We start with a model: A fully equipped model and pattern shop allows us to begin the process in a number of ways - from a supplied shrink model, prints, mylars, CAD data, or we can digitize an existing part. Models are CNC machined, with the final details finished by our skilled craftsmen, and then CMM checked to ensure complete accuracy.

A pattern is made: Once it is determined that dimensional tolerances and all details are met in the model, an exact rubber, plaster or epoxy pattern is made. Complex parting lines and unusual shapes shouldn’t be a problem.

Making the ceramic mold: A special, high heat-resistant ceramic material is then cast over the pattern. This ceramic material becomes a mold when cured. Only our patented process and advance technology can make it possible for the ceramic to incorporate even the most minute details of the original model, including its ribs and pockets. In fact, the more difficult the part would be to machine, the greater the benefit of the Dangios process. And since the pattern may be used for as many as one hundred times, you save on the cost of multiple molds.

Casting the metal: A full range of tool, alloyed and stainless steels can be cast, as well as advanced beryllium-nickel and beryllium-copper alloys. Locating lugs and bosses can be integrally cast, eliminating what would ordinarily be additional machining. Absolute metallurgical control, plus dense solid castings, are assured.

Finishing the casting: Dangios can do as little or as much finishing as you like. Finishing options include parting lines fitted, ground, EDMed and matched; backs or all six sides ground; wall stock established; and cavity and core surface finished in any grit required. Of course, all tolerances are fully checked with our CMM.