What is the Ceramic Shell Method? The ceramic shell method is a lost-wax method (other combustible materials can also be used). In this method, a wax model is made, around which a hard, heat-resistant shell is formed. The wax is then fired away, and the model is lost (hence the...
Remasol Adbond Advantage has an increased adhesion to wax surfaces making it an ideal primary binder. A ready to use solution, optimised for the best performance.
Burst 100 Antifoam provides outstanding performance under many different conditions. It is compatible with a wide variety of wetting agents, and can tolerate both alkaline and acidic binder systems.
Acid Yellow is a dye used as a drying indicator in the ceramic shell method. It changes color when drying, which helps to monitor the drying process and determine when the next layer can be applied, making the process more efficient.
Good quality fused silica for High thermal stability and low thermal expension. Results in a somewhat flexible shell, better aible to withstand cracks.
Ready to use instantly! Remove the lid and stir. Your slurry is now ready for use, as Jus-Dip doesn’t need to be constantly stirred you can dip directly from the container. After use the slurry can simply be stored away.
With Remasil 50 you can produce investment casting shells of excellent refractoriness and high temperature stability, at an incredibly economical rate.
Shellspen suspension powder keeps solid particles in ceramic slurries evenly distributed, eliminating the need for constant stirring. This makes the process of making ceramic molds more efficient and convenient.
Make 30 liters of slurry yourself, for the ceramic bowl method, which does not require continuous stirring. Includes 2 bags of aluminum silicate for stucco.
Calcined zircon ideal for high quality contact layer in the ceramic shell-lost wax process.
What is the Ceramic Shell Method?
The ceramic shell method is a lost-wax method (other combustible materials can also be used). In this method, a wax model is made, around which a hard, heat-resistant shell is formed. The wax is then fired away, and the model is lost (hence the name). The remaining hard shell is suitable for casting aluminum, including bronze.
Benefits of the Ceramic Shell Method
The ceramic shell method is a proven technique used in precision foundries for many years. It is also increasingly used in art foundries and is now often used alongside the fireclay method.
Fast firing - The resulting shell can be fired in 2 hours, which saves a lot of energy compared to the plaster/chamotte method.
Lighter weight - The shell is a lot lighter than a plaster or fireclay mould, which is also more pleasant to work with for many people
Simple process - Fairly easy for occasional use
The Ceramic Shell Process
The method involves a slurry made from a binding liquid, flour, and a sanding material. Through a repeated process of dipping in the slurry and applying sand, a multi-layered dish is built up over a period of several hours to days. The number of layers varies on average between 6 and 12. This process usually takes between 3 and 6 days.
The ceramic Shell method is fairly simple for occasional use, but if you want to use it continuously, it's helpful to establish a clear process. We're happy to guide you through this process.
3 Options for the Ceramic Shell
Option 1: Traditional Method
The original option and the most commonly used in larger foundries. This involves mixing a binder (a water-based silica and polymer suspension) with flour to create a slurry. Drying indicator, a crosslinking agent, and a defoamer may also be added. Note that our binder already contains crosslinking agent, defoamer, and polymer, so you usually do NOT need to purchase these separately.
Advantage: The products can be kept unmixed for many years. Disadvantage: The slurry must be continuously mixed after mixing. If the slurry sits for too long, it will gel and thicken, becoming unusable. Therefore, a mixing machine that runs 24/7, year-round, is required. This is often a problem for smaller users. Optionally, you can also mix a smaller quantity and use it all at once, perhaps by pouring the slurry over the model instead of dipping it.
Option 2: Ready-to-use Slurry
A very convenient second option is to use a ready-made slurry. The manufacturer will have already made a slurry for you from binder and flour. Even better, this slurry doesn't require constant stirring. It's for use only once a week. This slurry naturally contains all the components: binder, flour, wetting agent, defoamer, a suspension agent, and a drying indicator.
Due to the amount of work required to mix small packages in our warehouse every week, we only offer large packages here.
Disadvantage: You have no control over the type of flour used. Of course, you can adjust the fluidity and other factors by adding binder or flour yourself. Another disadvantage is that the shelf life is usually a maximum of one year.
We recommend that you also read the manual in option 1 to learn how to further maintain and adjust a slurry.
Option 3: Hybrid Method
The newest option we offer combines the two previous options. We provide all the materials to make your own slurry, as in option 1. However, with this process, you also add a third component (Shellspen suspension powder). This eliminates the need for continuous stirring!
This way you have all the benefits of option 1: maximum control over the slurry and maximum shelf life of the unmixed components, and the advantage of option 2 of no longer having to mix continuously!
We recommend that you also read the manual in option 1 to learn how to further maintain and adjust a slurry.
Manuals and Documentation
On this page, we offer all the products listed, as well as ready-made combinations, so you can see what's possible. Of course, it's best to contact us if you'd like to place a different combination or larger order.
We recommend that you read the above manuals carefully so that you have an idea of what is involved in the ceramic Shell process.
We also strongly recommend keeping a log of the slurry quality and what you've done to adjust it (or to prepare it the first time). An example can be found here:
Manual Ceramic Shell method V3.pdf