MACHINING & METAL CUTTING

MACHINING & METAL CUTTING
MACHINING & METAL CUTTING

Foundry Model Making with Sträfor by Evomatec – Precision and Efficiency in Machining and Metal Cutting

Advanced Sträfor Model Making for Industrial Casting

The foundry model making with Sträfor (expanded polystyrene) by Evomatec redefines precision, efficiency, and cost-effectiveness in modern manufacturing.
This advanced technology was specifically developed for high-precision casting and combines lightweight model engineering with state-of-the-art CNC machining and metal-cutting expertise.

Evomatec merges decades of foundry experience with modern subtractive manufacturing to produce molds, prototypes, and series tools that meet the highest industrial standards.
From the initial CAD design to the fully machined casting model, Evomatec provides every process step in-house — including turning, milling, drilling, hard machining, and surface finishing.

Sträfor as a Material for Modern Foundry Model Making

Sträfor (expanded polystyrene, EPS) is the modern standard material for casting model construction, thanks to its easy machinability, lightweight structure, and dimensional accuracy.
Evomatec uses densified Sträfor with a homogeneous cell structure, perfectly suited for CNC milling, high-speed cutting, and micro-machining.

Advantages of Sträfor in Model Making:

  • Lightweight yet highly dimensionally stable

  • Easy CNC and 5-axis machining

  • No thermal distortion during casting

  • Excellent surface finish after machining

  • High dimensional precision for accurate cast components

These properties make Sträfor the ideal material for Evomatec’s precision foundry model making, especially when paired with cutting-edge machining technology.

CNC Machining in Foundry Model Making – Precision Starts in Detail

CNC machining forms the core of Evomatec’s production process.
Using computer-controlled machining centers, Sträfor models and casting molds are produced with micron-level accuracy.

Evomatec’s CNC technology enables:

  • Highly accurate model geometries with tolerances < ±0.02 mm

  • Repeatable serial production

  • Seamless machining of complex freeform surfaces

  • Fully automated multi-axis milling systems

Powered by advanced CAM software (SolidCAM, Siemens NX, Catia), every step of the process — from simulation to execution — is digitally controlled and verified.

Precision Machining – The Key to Dimensional Perfection

In foundry model making with Sträfor, machining precision is the bridge between the raw model and the finished mold.
Evomatec utilizes a broad spectrum of subtractive processes, from deep drilling to high-speed and hard milling.

Core Machining Processes at Evomatec:

  • Rough machining – accurate block preparation for further shaping

  • Milling – 3- to 5-axis contour processing for all model types

  • Turning – rotationally symmetrical precision parts

  • High-speed cutting (HSC) – ultra-fast surface processing

  • Hard turning and milling – fine machining of hardened materials

Through optimized cutting parameters, tool paths, and cooling techniques, Evomatec achieves maximum productivity with minimal tool wear.

Turning – Runout Accuracy for Complex Casting Geometries

Turning is a key discipline within Evomatec’s manufacturing process, particularly for rotational and symmetrical components.
Modern CNC lathes with driven tools integrate drilling, threading, and milling operations in a single setup.

Advantages:

  • High runout precision

  • Perfect surface quality through optimized cutting speeds

  • Combined turning-milling capability on one machine

  • Automated material feed for serial production

This precision turning ensures perfect fits for parts such as housings, hubs, bearings, and valve bodies.

Milling – Accurate Contours for Casting Models

Milling allows complex 3D geometries to be created with absolute accuracy.
Evomatec employs simultaneous 5-axis machining centers to reach every shape, curve, and angle of a casting model.

Key Features of Evomatec Milling:

  • 5-axis machining for complex freeform geometries

  • High-precision cutting with superior material removal

  • Micro-milling for ultra-smooth surfaces

  • Adaptive tool compensation for consistent precision

Each casting model is digitally scanned and measured before proceeding to the next stage of production.

5-Axis Machining – Maximum Freedom in Model Geometry

5-axis technology is one of Evomatec’s specialties.
It enables simultaneous movement across all spatial axes, ideal for models with undercuts, cavities, or intricate geometries.

Advantages of Evomatec 5-Axis Machining:

  • One setup for multiple sides

  • Maximum form accuracy and stability

  • Reduced machining time

  • Precise contour shaping for complex geometries

This advanced system increases productivity and casting precision, ensuring consistent quality across all production batches.

High-Speed Cutting (HSC) – Speed Meets Precision

Evomatec’s HSC machining operates at extremely high spindle speeds and cutting rates.
The result is a mirror-smooth surface combined with rapid material removal.

Benefits of HSC Technology:

  • Shorter production cycles

  • Polishable surface finishes

  • Lower thermal stress and deformation

  • Extended tool life and lower wear

HSC is ideal for fine molds and functional casting models, where top-tier precision is non-negotiable.

Precision Machining – Micron-Level Accuracy for Every Surface

In precision machining, Evomatec achieves dimensional accuracy down to the micrometer.
Each movement, cut, and surface is executed under continuous digital monitoring.

Applications:

  • Models for investment and aluminum casting

  • Core forms and inserts requiring tight tolerances

  • High-quality surfaces for serial molds

With automated measurement systems and CNC process control, Evomatec guarantees repeatable precision in every detail.

Surface Finishing – Perfect Texture for Perfect Castings

Surface finishing represents the final stage of perfection.
Evomatec uses grinding, polishing, lapping, and laser texturing to achieve the ideal surface for casting.

Objectives of Surface Finishing:

  • Reduction of roughness and porosity

  • Improved mold release and castability

  • Extended mold life

  • Enhanced visual and functional appearance

This ensures that all models and molds deliver clean, smooth, and defect-free castings in serial production.

Machining Tolerances and Quality Assurance

Evomatec maintains extremely tight machining tolerances across all production lines.
Each part is measured using tactile and optical 3D scanning systems and CMM technology to ensure absolute conformity.

Typical Tolerance Ranges:

  • Dimensional tolerance: ±0.02 mm

  • Runout: <0.01 mm

  • Flatness: <0.015 mm

Such precision guarantees perfect alignment and casting consistency even in high-volume manufacturing.

Hard Turning and Hard Milling – For Heat-Treated Materials

Evomatec uses hard turning and milling as efficient alternatives to grinding for hardened tools and dies.
This machining approach produces flawless surface finishes with minimal rework.

Advantages:

  • Reduced processing time

  • Lower tool wear

  • Surface roughness values below Ra 0.2 µm

Ideal for durable molds exposed to high temperatures and pressures during casting operations.

Deep Drilling, Micro-Milling, and Thread Cutting – Detail Precision Inside and Out

Evomatec performs deep hole drilling, micro-milling, and thread machining to perfection.
These capabilities are crucial for casting molds requiring cooling channels, inserts, or micro-features.

Capabilities:

  • Drilling depths up to 1 meter with perfect straightness

  • Micro-milling as fine as Ø 0.2 mm

  • CNC thread cutting from M1 to M100

These fine-tolerance operations ensure functional, precisely fitted casting models for every application.

Raw Material Processing and Multi-Axis Milling – Efficiency from Start to Finish

Evomatec automates raw block preparation and shaping, from cutting Sträfor blocks to multi-axis precision milling.
Modern multi-axis systems can process multiple components simultaneously, increasing output while maintaining precision.

Advantages:

  • Shorter lead times

  • High repeatability and minimal setup time

  • Optimized workflow for serial and large-scale production

This seamless process ensures maximum productivity from raw material to finished model.

Machine Tools and Machining Centers – The Core of Production

Evomatec operates a fleet of high-precision machining centers and CNC systems that guarantee consistency, flexibility, and scalability.

Equipment Portfolio:

  • 3-, 4-, and 5-axis machining centers

  • Turn-mill combination machines

  • High-speed HSC systems

  • Robot-automated loading systems

With this advanced infrastructure, Evomatec delivers stable, repeatable precision across all production processes.

Process Monitoring, Quality, and Documentation

Every step of production is monitored and documented in real time.
Sensors and temperature tracking ensure dimensional accuracy within defined tolerances.

Evomatec’s ISO-certified quality management system ensures full traceability of every machining parameter.

Conclusion – Evomatec: Precision in Sträfor Models and Machining Excellence

Foundry model making with Sträfor by Evomatec stands for technical perfection, productivity, and dimensional accuracy.
Through the integration of advanced machining technology, intelligent CNC systems, and decades of foundry expertise, Evomatec provides the industry with everything it demands: precision, speed, and reliability.

Evomatec – Precision. Performance. The Future of Foundry Model Making.


Contact our sales team: info@evomatec.de

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