For patterns of this massive scale (3 to 5 meters wide), metal would be too heavy to handle and extremely expensive to machine. Laminated hardwood or epoxy provides the perfect balance of strength, dimensional stability, and ease of modification while being light enough for foundry cranes to lift.

The pattern is designed with an extensive Riser and Gating System. We also provide a specialized Core Box with integrated venting channels that allow hot gases to escape during the pouring of molten iron, preventing porosity.

A Class A Epoxy/Wood pattern can easily produce 500 to 1,000 high-quality molds if maintained properly. We apply a specialized moisture-resistant lacquer that protects the pattern from the abrasive nature of the foundry sand.

Since these are Custom Toolings, they are usually specific to one design. However, our modular design allows us to swap certain core segments or flange inserts to accommodate minor design variations without building a completely new pattern.

For SG Iron used in wind hubs, the shrinkage is significant. We use advanced Foundry Simulation Software to calculate a precise "Scale Factor" (usually around 1% to 1.5%), making the pattern slightly larger so the final cooled casting is exactly the right size.