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Precision Engineering at Shubh Mangal Techno

At Shubh Mangal Techno, we manufacture Dies (Patterns/Tools) using the latest CAD/CAM technology, ensuring the highest levels of accuracy and efficiency. We also provide expert technical support to help you develop cost-effective, high-performance products.

Our expertise extends to the injection and production of wax patterns from Dies, with each wax pattern undergoing 100% dimensional checks for unmatched precision. Once formed into a tree or cluster, these wax patterns enter the ceramic coating process, which is conducted in climate-controlled rooms to guarantee exceptional dimensional accuracy and superior surface finish.

The de-waxing process follows, where the ceramic mould is immersed in a hot wax bath for wax removal. Depending on the casting’s size and geometry, the ceramic moulds are baked at temperatures ranging from 900°C to 1150°C, and molten metal is poured into them to form the final product.

After casting, the products go through a comprehensive finishing process, including Gate Cutting, Machining, Sand Blasting, Shot Blasting, Leaching, and Deburring, ensuring top-quality results.

Our heat treatment process is tailored to meet specific material requirements, with every cycle carefully recorded and documented. Our fully calibrated heat treatment furnace ensures the best results every time.

Each casting undergoes a 100% visual inspection, with critical dimensions meticulously checked before packaging and shipment. We also offer castings in a machined condition and provide a range of finishing options, such as passivation, electro-polishing, blackening, powder coating, shot blasting, and glass bead blasting.

1. Wax Injection

The process starts with producing a heat-disposable pattern, typically created by injecting wax into a metal die or mold. This is done using a Horizontal Automatic Injection Machine. A water cooling system is integrated to minimize cycle time and ensure precise dimension control of the pattern. For even tighter dimensional accuracy, pattern resting gauges are employed.

2. Pattern Assembly

The wax patterns are attached by the gate to a central wax runner system. The runner system is called a sprue. Patterns, runners, and pouring cup compromise the cluster or tree. Radius is provided to all joints between pattern and runner. Same checked thoroughly before coating to avoid rejection due to sand inclusions.

3. Shell Building

The shell-building process involves dipping the assembly into a ceramic slurry, followed by a fine sand coating. This cycle is repeated 4 to 6 times, with each layer air-dried under controlled conditions, maintaining a temperature between 22–26ºC and optimal humidity levels. To enhance efficiency, organic fiber is added to the secondary slurry bath, reducing cycle time and the number of coats required. This also improves the permeability of the shells, ensuring better results.

4. Dewax Operation

Once the shell is completed, it is placed in a steam autoclave where the wax pattern melts and exits through the gates and pouring cup. The autoclave de-waxing process preserves the quality of the wax, offering superior results compared to conventional de-waxing methods.

5. Shell Pre Heating

The ceramic shell molds are fired to remove any remaining pattern material and preheat them for casting, typically at temperatures ranging from 800°C to 1100°C. At Shubh Mangal Techno, we use a rotary hearth furnace equipped with three burners, allowing for precise temperature control throughout the shell firing process.

6. Metal Pouring

The preheated shell is filled with molten metal by gravity pouring. As the metal cools, the parts, gates, sprue, and pouring cup become one solid casting.

7. Gate/Riser Cutting

After the metal solidifies and cools, the ceramic shell is then removed by vibratory methods or water blasting.

8. Heat Treatment

Casting to be shot Blasted to remove all small ceramic particles. Amtech also can supply casting with glass bead blasting or sand blasting if customer require.

9. Shot Blasting

Individual casting are removed from the cluster by means of a cut off wheel or weld cutting.

10. Finishing Operation (Gate Grinding)

Remaining gate protrusions are removed by belt grinding.

11. Final Casting Inspection

Casting is Heat Treated as per Specifications in 1 ton. capacity heat treatment furnace. Same has been calibrated as per standard APA 6 A.

12. Machining

Finally casting is dimensionally and visually inspected, packed as per customer specification and dispatched. Before Despatch All testing to be done like Die Penetrate Test, Magnetic Particle Test, Radiography Test etc. based on customer specification.

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