Design Element | Suggestions | Reasons and Benefits |
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Wall Thickness | Recommended range: 1.0 - 5.0 mm (ideal ~2.5 mm) | Ensures even cooling, minimizes distortion, porosity, and reduces weight and cost. |
Corner Radii | Minimum internal radii: 0.5 - 1.0 mm | Reduces stress concentrations and helps metal flow smoothly, minimizing defects. |
Draft Angles | Draft typically not required | Investment casting molds (ceramic shells) break away easily, eliminating the need for drafts. |
Fillets | Minimum internal fillet radius: 0.5 mm | Improves molten metal flow, reduces stress concentrations, and increases strength. |
Hole Sizes | Minimum hole diameter: 1.5 mm | Ensures reliable mold filling, maintains integrity, and prevents defects or incomplete casting. |
Undercuts | Allowed, but minimize complexity | Investment casting easily handles undercuts, but reducing complexity simplifies mold design and reduces cost. |
Surface Finish | Typical surface roughness: Ra 3.2 - 6.3 µm | Provides a high-quality surface finish directly from casting, reducing post-processing requirements. |
Tolerances | Typical linear tolerance: ±0.13 mm per 25 mm | Balances accuracy, process capability, and cost-effectiveness in manufacturing. |
Text and Logos | Raised or recessed text/logo ≥ 0.4 mm depth/height | Ensures clear, readable marking directly from the mold. |
Ribs and Gussets | Thickness approximately 60-80% of adjacent walls | Provides optimal reinforcement without shrinkage or internal stresses. |
Part Complexity | Allow complex designs, but simplify where possible | Investment casting supports intricate shapes, but simplicity reduces costs, defects, and improves yield. |
Gate Locations | Place gates at thickest cross-sections | Promotes uniform filling, reduces turbulence, shrinkage, and casting defects. |