FOUNDRY MODEL MAKING

Evomatec Foundry Model Making – Precision, Technology, and Robotics for Perfect Casting Results

Innovation Meets Tradition in Industrial Model Engineering

Evomatec’s foundry model making combines decades of expertise in mold making with cutting-edge CNC machining technology and robotic automation. This powerful synergy delivers maximum dimensional accuracy, shorter production times, and outstanding repeatability for all industrial casting processes.
From prototypes and small batches to fully automated serial production, Evomatec develops customized solutions where precision, reproducibility, and durability are essential.

With Evomatec casting models, complex castings can be manufactured more efficiently, cost-effectively, and consistently at the highest quality. Advanced techniques such as 5-axis CNC machining, CAD/CAM design, reverse engineering, shrinkage compensation, robotic integration, and digital simulation are key elements of this approach.

The Role of Foundry Model Construction in Modern Industry

In industrial manufacturing, foundry model construction is far more than the creation of a mold — it is the core of the entire casting process. The precision and quality of the model determine the surface finish, accuracy, and dimensional consistency of the final casting.
A high-quality model minimizes rework, reduces scrap, and ensures production stability.

Evomatec integrates model construction as a systemic part of the entire production chain. By combining digital technologies, automated CNC machinery, and robot-assisted manufacturing systems, Evomatec achieves a new level of precision and cost-efficiency.

The integration of robotics, precision engineering, and intelligent process planning provides a competitive edge in quality, time, and cost, fully aligned with the Industry 4.0 Smart Factory philosophy.

Model Splitting and Mold Release – Perfect Separation for Smooth Casting

A key criterion in model construction is model parting, which defines how the model is divided into upper and lower mold halves for smooth demolding after casting.
Evomatec analyzes the ideal parting line during the design phase to prevent undercuts, distortions, and material tearing.

Technical Advantages

Precisely defined parting lines for flawless demolding
CAD-based simulation of mold separation
Inclusion of undercuts and mechanical ejectors
Adaptation to both machine molding and manual molding systems

This optimized design ensures reliable functionality, reduces maintenance needs, and extends the model’s lifespan significantly.

Shrinkage and Dimensional Accuracy – Precision Begins in Design

During cooling, every casting metal contracts — known as shrinkage. If not properly compensated, it leads to dimensional deviations or internal stresses.
Evomatec integrates shrinkage factors directly into the digital CAD model. By calculating material contraction, each model is pre-dimensioned to ensure the final casting meets exact specifications.

Evomatec Shrinkage Compensation Advantages

Software-based calculation for all casting alloys
Automated dimensional adjustment in the CAD/CAM workflow
CNC precision within ±0.02 mm
Temperature compensation during machining

This results in dimensional stability far exceeding industry standards, a critical advantage for aerospace, automotive, and mechanical engineering castings.

Cores, Core Boxes, and Ejector Mechanics – Precision in Every Detail

Cores create the internal cavities and contours of the casting and require extremely precise manufacturing.
Evomatec produces core boxes and models with the highest precision — using CNC milling, additive manufacturing, or hybrid technologies.

Integrated ejector systems ensure safe, damage-free removal of cores and models. Intelligent spring mechanisms, pneumatic systems, and robot-assisted extractors minimize cycle times and extend mold life.

Technical Highlights

CNC-machined core boxes made from aluminum, steel, or composite resin
Polished cavities for precise form alignment
Automated ejector systems for robotic handling
Adaptable to molding and core-shooting machines

Material Selection – Strength, Longevity, and Cost-Efficiency

Depending on production requirements, Evomatec selects materials that balance durability, machinability, and cost efficiency.
From hardwood for small batches to metal molds for high-volume production, each material is chosen to withstand thermal and mechanical stresses.

Commonly Used Materials

Wood models: lightweight and ideal for prototypes
Resin and plastic boards (e.g., Ureol): high dimensional stability
Metal models (aluminum, steel, cast iron): robust and wear-resistant
Foam and hybrid models: suitable for rapid prototyping

With polished and sealed surfaces, these models guarantee exceptional surface quality and consistent performance even after hundreds of casting cycles.

Surface Finish and Coating – Perfect Casting Surfaces

The surface quality of a casting is determined by the finish of the model surface.
Evomatec ensures smooth transitions, precise radii, and polished textures, enhanced by specialized coatings that reduce wear and facilitate cleaning.

Surface Processing Advantages

CNC-finished, reproducible precision
Chemical and thermal sealing for durability
Minimal sand adhesion
Extended model lifespan
Superior casting surface finish

This level of refinement is particularly vital for aluminum, stainless steel, and gray iron castings.

Manufacturing Processes – From Craftsmanship to 5-Axis CNC

Evomatec combines traditional craftsmanship with state-of-the-art CNC machining.
Alongside manual finishing and grinding, 5-axis machining centers handle even the most complex geometries in a single run.

Manufacturing Techniques

CNC milling (3–5 axes)
Grinding and manual refinement
Wire and sink EDM
3D printing and additive manufacturing
High-speed cutting for fine surfaces

This hybrid approach ensures a perfect balance of automation and craftsmanship.

CAD/CAM Design and the Digital Process Chain

Every project begins with a digital 3D model. Using modern CAD software (SolidWorks, Siemens NX, Catia, Autodesk Inventor) and advanced CAM systems, Evomatec creates precise toolpaths and production data.

Shrinkage, undercuts, parting lines, and ejection systems are integrated directly into the design. This ensures that CNC production runs seamlessly with zero deviation.

Digital Workflow Benefits

Full traceability of model versions
Automated toolpath optimization
Simulation of thermal expansion and mold release
Direct robotic control integration

Reverse Engineering – Digitizing and Reconstructing Legacy Castings

Many foundries rely on older castings without existing digital models.
Evomatec’s reverse engineering service precisely scans, measures, and reconstructs parts using 3D scanning, photogrammetry, and laser measurement.

These data are converted into CAD models, optimized, and adapted for modern manufacturing.
This process enables reliable reproduction of historic, damaged, or undocumented castings.

Typical Applications

Reconstruction of machine components
Adaptation to new molding technologies
Serial reproduction without drawings
Digitalization for CAM production

Molding Boxes and Mold Construction – Precision in Every Interaction

The molding box integrates all essential components — model, core, ejector mechanics, and shrinkage compensation.
Evomatec designs boxes suitable for machine, hand, or shock molding, ensuring ergonomics, strength, and reusability.

Molding Box Technologies

Mechanically interlocked systems for serial casting
Quick-change mechanisms for flexible production
Integrated cooling and temperature regulation channels
Sensor-based monitoring and quality control

Fixtures and Assembly Aids – Accuracy and Alignment

Evomatec produces custom fixtures, jigs, and clamping systems for accurate assembly and measurement.
These ensure precision during handling, machining, and demolding — vital for robotic production environments.

Examples

Measuring fixtures for castings
Clamping systems for machining and mold extraction
Robotic grippers and automated alignment tools
Calibration aids for molding machines

Quality Assurance and Precision Measuring Systems

Quality control is an integral part of Evomatec production.
Each model undergoes 3D scanning, tactile measurement, and digital CAD comparison before approval.

Quality Systems

Optical and tactile measurement systems
CAD nominal/actual comparison
Temperature tracking during machining
Certified inspection reports (ISO 9001 & CE standards)

This ensures consistent, verified accuracy, regardless of batch size or complexity.

Temperature Management and Thermal Compensation

Thermal influences can distort model geometry.
Evomatec compensates thermal expansion through intelligent design, material selection, and active cooling systems.

Benefits

Stable geometry under variable conditions
Precisely defined tolerance zones
Extended lifespan and minimal maintenance

Prototype Model Construction – Fast, Reliable Development

For experimental casting and small series, Evomatec offers flexible prototype modeling using lightweight materials and additive manufacturing.
These allow functional testing, flow analysis, and fit evaluation before final production.

Prototype Services

Rapid development in a few days
CAD-based modification and optimization
Functional test casting and validation
Easy transition to serial production

Serial and Exchange Models – Efficiency in Mass Production

Evomatec designs modular serial and exchangeable models for high-volume foundries, enabling quick retooling and minimal downtime.

Features

High repeatability with identical output
Modular systems for fast changeovers
Robot-compatible interface design
Durable materials for thousands of cycles

Robotics and Automation in Foundry Model Construction

Evomatec integrates industrial robots, SCARA systems, Delta robots, and Cobots into the model-making and molding process.
These robots perform automated handling, assembly, core removal, and cleaning tasks with speed and precision.

Robotic Systems in Use

Articulated robots for flexible six-axis movement
SCARA robots for horizontal precision handling
Delta robots for high-speed pick & place
Cobots for safe human-robot collaboration

This integration combines traditional craftsmanship with the future of industrial automation.

Sustainability and Resource Efficiency

Evomatec’s modern foundry model production emphasizes sustainability and energy efficiency.
Through digital simulation, optimized toolpaths, and recyclable materials, waste and energy consumption are significantly reduced.

Industries and Application Fields

Automotive: Engine housings, suspension components
Mechanical engineering: Gearboxes, hydraulic blocks, structural parts
Aerospace: Precision aluminum and titanium castings
Energy sector: Turbine components, heat exchangers
Research and prototyping: Trial castings and small-batch production

Conclusion – Evomatec Foundry Model Construction: Precision in Every Dimension

Evomatec’s foundry model construction represents more than just mold manufacturing – it is a digitally driven, high-precision system for ensuring casting quality from start to finish.
Through robotic integration, CAD/CAM precision, shrinkage correction, and rigorous quality assurance, Evomatec sets new benchmarks in modern foundry technology.

Whether for prototype development, serial production, or fully automated casting, Evomatec delivers precision, reliability, and efficiency at the highest industrial level.

Contact our expert team: info@evomatec.de