EXPANDING PATTERNLESS CAPABILITIES
21 May 2006 - Castings Technology International

The demand for Cti's sand machining expertise has been on the increase for some time as more and more companies realise the benefits of the Patternless process - invented and developed at Cti for directly machining moulds and cores from blocks of sand. The company's commitment to deliver ever improving services to their customers has led to the investment in a CNC machine with an overall working envelope of 3.6 x 3.6 x 1.2m, with full 5-axis machining capability, bigger, better and faster than its predecessor.

This new facility not only means that larger products can be machined, but that there is more greater scope to increase the number of smaller parts machined sequentially. In addition, the machine offers better dynamic machining capability, improved accuracy and faster machining rates.

The machine is currently being used to machine sand moulds for an order of five-blade, fixed-pitch propellers - one of several orders received since the new equipment arrived. Previous work has included the production of large-scale aluminium aerospace technology demonstrators using the Patternless process and the development of production replicant one-offs - demonstrating the ability of the technology to 'get it right first time'.

In addition to machining sand, the facilities have the ability to machine a multitude of other materials, including polystyrene, wood (MDF, plywood), resins (model board) and aluminium. Indeed, Cti has made large-scale production pattern equipment for use in a member's foundry, and even taken on the responsibility of producing castings using this pattern equipment until the destination foundry was able to take on the business, as part of Cti's Business Incubation service.

Features of Cti's Patternless System
- working envelope of 3.6 x 3.6 x 1.2m;
- rough machining of a mould cavity equivalent to one tonne casting in 30 minutes;
- machining accuracy of ±0.01mm;
- uses specially developed cutters with minimal wear;
- uses block of sand (up to 10,000kg) readily made in any foundry from new or reclaimed sand.

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