Pattern Forge is a cutting-edge, high speed automatic pattern making machine designed to help Sand Casting Industry to make patterns in a faster way. Pattern Forge streamlines the pattern making process, delivering unparalleled efficiency, precision, and cost savings. It is used to produce near net shape patterns and significantly reduce the time, labor and materials typically required for traditional pattern making process.
Engineered for versatility, it seamlessly handles intricate patterns for a wide range of industries, including automotive, aerospace, and tooling. Powered by advanced automation technology, the pattern forge ensures consistent output, drastically reducing production time while maintaining exceptional accuracy.
The process begins with DE Thermo Fiber resin, a unique material developed by Deltasys E-Forming Company. This resin is specifically formulated for making patterns.
The resin is melted using a positive displacement pump, which ensures a consistent flow. The melted resin is then pushed through a wide orifice and precisely deposited into a heated substrate plate of the desired size.
The operator programs the machine to follow the desired pattern-geometry. The pump deposits the resin layer by layer until the pattern reaches its near-net-shape. This automated process eliminates the need for manual intervention, ensuring consistency and accuracy.
Once the near-net-shape is achieved, the pattern undergoes a final shaping process using a CNC milling head. This step refines the pattern to its exact specifications, ensuring precise dimensions and smooth surfaces.
The CNC milling head can be programmed to accommodate various pattern designs and complexities, providing the flexibility to produce patterns for different casting requirements.