Sarcol provides a unique set of services for it's customers who have complex and detailed product designs that can't be produced through conventional machining technologies.
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Sarcol can utilize its patented ceramic cast-to-size technology to produce "net shape" mold cavities, inserts and cores.
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THE SARCOL PROCESS
A PLANT TOUR

We start with a model.

SARCOL's fully equipped model and pattern shop allows us to start the process in a number of ways. We can build models from a variety of sources including supplied shrink model, prints, mylars, CAD data, or we can digitize an existing part. SARCOL can also take existing part pieces for which prints may have been lost and create a new mold while taking into account shrinkage issues. Final details are CMM checked to insure complete accuracy.

A pattern is made from the model.

Once dimensional tolerances and all of the details are determined, in the model, an exact pattern made out of rubber, plaster or epoxy pattern is prepared. Complex parting lines and unusual shapes can be easily built into the model and later into the final cast metal mold. Ongoing cost savings are afforded to our customers due the fact that the pattern may be used several times with the same high tolerances as the very first.

The critical next step is making the ceramic mold.

Next, in the cornerstone of the patented SARCOL PROCESS, a special, high heat-resistant ceramic material is poured over the pattern. The ceramic material blend incorporates the most minute details of the original model, including ribs and pockets. After being cured, the ceramic material becomes a hardened mold.

Casting the metal in the foundry.

A full range of metals and alloys can be cast in ceramic molds using the SARCOL PROCESS including a full range of tool steels, nickel, iron and beryllium-copper (same as Mold Max billet that machine shops purchase). All of the complex details captured in the hardened ceramic mold can be integrally cast, eliminating what would ordinarily require additional machining.

Finishing the casting is last.

SARCOL can perform a wide variety of finishing operations based upon our customers particular needs. Finishing options include: parting lines fitted, ground, EDMed and matched; backs or all six sides ground; wall stock established; and cavity and core surface finish in any grit required. Tolerances are fully checked with our CMM and other quality control techniques.


Compare the Sarcol Process with other competing processes

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Compare the Sarcol Process with other competing processes (745 KB)

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Our CNC machining center produces models that precisely replicate your CAD data, mylar, or supplied part.

Our CNC machining center produces models that precisely replicate your CAD data, mylar, or supplied part.

Precise digitizing and dimensional verification is assured with our computer controlled CMM.

Precise digitizing and dimensional verification is assured with our computer controlled CMM.

This rubber pattern produces an exact replica of the leather-wrap model.

This rubber pattern produces an exact replica of the leather-wrap model.

SARCOL's foundry is capable of producing finished castings up to 1,500 pounds.

Click image below for film of process step

Sarcol's foundry is capable of producing finished castings up to 1,500 pounds.

Sarcol's skilled craftsmen perform a wide variety of finishing operations.

Sarcol's skilled craftsmen perform a wide variety of finishing operations.

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