Investment casting, also known as lost-wax casting, is a manufacturing process that involves creating a wax or plastic pattern, coating it with ceramic material to create a mold, and then using the mold to produce a precision metal part. Injection wax molding is a common method used to produce the wax patterns, where wax is injected into a metal mold under pressure to create accurate, repeatable patterns. Key steps in injection wax molding include wax preparation, injection molding, pattern removal, assembly, shell building, dewaxing, and metal pouring. Parameters like melt temperature, injection pressure, and part geometry must be optimized. Filled wax, which contains fillers and minerals, is often used due to its

1. INJECTION
WAX MOLDING
-RANJITH

2. INTRODUCTION
Investment casting, also known as lost-wax casting, is a manufacturing process in which a wax or plastic pattern is coated
with a ceramic material, and then heated to create a mold. The mold is then filled with molten metal to create a precision part
with intricate details and smooth surfaces. Investment casting is commonly used to produce parts for the aerospace,
automotive, and medical industries.

3. STEPS INVOLVED
1. Pattern creation
2. Investment
3. Dewaxing
4. Pouring
5. Cooling
6. Shell removal
7. Finishing

4. PARAMETERS
1. Pattern Design
2. Material selection
3. Investment thickness
4. Pouring temperature
5. Cooling rate
6. Surface finishing
7. Tolerance
8. Shell removal
9. Repeatability

5. TYPES OF INVESTING CASTING
1. Wax lost process
2. Soluble core process
3. Vacuum process
4. Shell molding casting process
5. Micro investment sand process

6. APPLICATIONS
1. Aerospace and defense
2. Power generation
3. Automotive
4. Oil and gas
5. Space exploration
6. Medical / orthopedics
7. Agriculture
8. Construction
9. Commercial and consumer products.

7. INJECTION WAX MOLDING
 Injection wax molding is a manufacturing process used in investment casting to produce wax patterns that are later used
to create metal parts. In this process, a wax material is injected into a metal mold under pressure, which results in a high-
quality, accurate and repeatable wax pattern.
 Injection wax molding is similar to plastic injection molding where wax is used instead of plastic.
 Waxes used – filled pattern wax, non filled pattern wax, runner wax, water soluble wax, sticky wax.

8. STEPS INVOLVED
 Wax preparation
 Injection molding
 Pattern removal
 Assembly
 Shell building
 Dewaxing
 Preheating
 Pouring
 Cooling and solidification
 Shell removal
 Finishing

9. PARAMETERS
1. Melt temperature
2. Injection pressure
3. Injection speed
4. Cooling time
5. Mold temperature
6. Ejection force
7. Material viscosity
8. Part geometry

10. FILLED WAX
 Filled wax is one of the synthetic wax made from chemical compounds and often used as a substitute for natural wax,
which are obtained from plants and animals.
 It is combined with fillers and minerls (Cu, Ca, Fe, Mn, Na, Zn) to increase its properties.
 They are enhanced properties like high melting point, higher stability and best resistance to heat and moisture, consistent
quality and color which is not in case of natural wax.
 Wide range of application in candle making, wax carving, lubrications, wood finishing, crayons etc.

11. LITERATURE SURVEY
AUTHOR AND PAPER DETAILS INFERENCES
• Chil-Chyuan Kuo and Ren-Lung Tsai
‘Fabrication and Application of Low-pressure Wax
Injection Rapid Tooling’
In this study, silicone rubber molds are used for low Pressure wax injection moldings were
fabricated. The optimal processing conditions in the wax injection molding process were
investigated using the Taguchi method . The characteristics of the injected wax patterns were
investigated.
• Chil-Chyuan Kuo & Wei-Hua Chen & Xue-Zhe
Liu & Yi-Lin Liao & Wei-Je Chen & Bo-Yu
Huang & Ren-Lung Tsai
‘Development of a low-cost wax injection mold with
high cooling efficiency’
1. In this study, three kinds of cooling-channel layouts were employed to fabricate wax
injection molds for low-pressure wax injection molding using rapid prototyping and rapid
tooling techniques.
2. The cooling effect of the straight-line channel is inferior to the conformal cooling channels
because conformal cooling channels have uniform distance between mold surfaces and the
center of cooling channels.
3. The copper ducts are widely used to make cooling channels because of simplicity of
processing.

12. • RAHMATI Sadegh, REZAEI Mohamad Reza,
AKBARI Javad
‘Design and Manufacture of a Wax Injection Tool for
Investment Casting Using Rapid Tooling’
1. A rapid wax injection tool of a gearbox shift fork was designed, simulated, and
manufactured using rapid prototyping and rapid tooling technology to save time and
cost of producing wax models used for the investment casting process.
2. This research aimed at investigating the feasibility of applying rapid prototyping and
rapid tooling technology into the wax model production for investment casting process.
• P D Kale, P D Daradeand A R Sahu
‘A literature review on injection molding process based
on runner system and process variables’
This paper focuses on the effectiveness of hot runner systems and scrap reduction of the
process by replacing the cold runner system with the hot runner