
Component
Prototype In-line static braided mixer (heat exchanger)
Application
Polymer, plastic, pulp, food and energy, aerospace, EV and ICE automotive
Metal
Aluminium A356
Process
Lost-wax, plaster-based, block investment casting
Casting Weight
40g (measuring 125mm x 22mm diameter and a wall thickness <0.4mm)
Project Information
To challenge the seemingly self-perpetuating nature of messaging surrounding metallic additive manufacturing (MAM) this technology, Sylatech undertook to explore whether its casting process could match MAM for design complexity, surface finish, alloy choice and mechanical properties.
Technical details
- The braided mixer had been designed for MAM with very complex internal geometries.
- It was not clear if the complex shape could be completely filled and effectively fed with wall thicknesses of <1mm.
- Boroscope used to facilitate post processing challenge of plaster removal.
Outcome
Working with AM design consultancy Metamorphic AM, a hybrid approach was agreed combining AM and plaster casting. CFD simulation enabled a feedback loop to be employed to optimise the runner systems and pouring temperature.
The success of the project has led to new work with Metamorphic AM, Photocentric and WMG and two automotive giants.
The component results are helping to re-establish casting as the sustainable process of choice for the design and volume production of complex parts, requiring excellent surface finish.



