The Précicast plaster-moulding process uses two-part demountable moulds, similar to sand-casting moulds. If cores are required, they are made separately in core boxes and then inserted into two half-parts to form the required cavities.
Plaster moulds are made by mixing plaster, refractory materials and water. The resulting mixture is cast onto models and hardened for 5-15 minutes.
Drying is a critical step of mould making, as all the moisture must be removed to prevent contamination from the gas that releases from the steam when liquid metal is poured into the moulds.
The insulating properties of dry plaster moulds prevent the metal from cooling to quickly, thus enabling a slow solidifying process that lets the aluminium flow into the thinnest mould sections. Moreover, the moulds are permeable, which allows the gases to vent out of the metal.
Once the metal is fully solidified, the moulds are carefully dismantled and the cast and feed systems are removed. The finishing process involves removing the separation lines, sanding, and/or acid washing.