Wax injection is performed using equipment developed from the latest in closed loop control plastic injection technology that achieves improved dimensional stability and superior surface finish. This process also enables the use of a wide range of pattern materials that can be changed easily and quickly so that the best recipe for any given component type can be used. This equipment provides great opportunity for process development of both pattern materials and the injection process itself.

The Medicast process has been designed around orthopaedic implant products enabling us to develop a system based on small moulds, which delivers a number of significant advantages. Small moulds require fewer shell coats but integrity is maintained by using appropriate materials with excellent high temperature stability and a fully automated coating cell ensures that consistency is maintained. Mould designs are largely symmetrical which provides improved consistency of product.

Flash fire treatment of moulds enables dewaxing, firing and preheating to be completed in a single preprogrammed cycle so repeated thermal cycling of moulds is eliminated. Cluster designs have been developed that do not cause mould cracking during dewaxing, a common cause of ceramic inclusions in investment castings.
Cast weights can be made small, enabling semi-automatic casting with a single -shot crucible, yielding excellent cast cleanliness. The Medicast casting unit design is patent pending.

The principal advantage of using small moulds is that a greater degree of control can be achieved throughout the process and reliance on operator expertise is reduced, ensuring consistency between batches. The post cast operations are conducted using standard equipment but as with the remainder of the facility, they have been structured to accommodate orthopaedic products specifically. At present, non destructive testing and thermal treatments are sub-contracted but dimensional inspection is conducted in-house using a CMM and Medicast has the capability for manual layout as required.