Lost Wax Casting Process

Our unique block moulding version of the lost-wax casting method affords customers a process capable of producing small and lightweight components.


Precision engineering

Our specialist process affords us the ability to take a customer’s concept and achieve reality in a fast and cost-effective manner. By combining our investment casting technology with best practice CNC machining, our capability can overcome many of the constraints placed on engineering design.

The Sylatech casting process provides a fast and cost effective method for both small batches and large quantities up to 150,000 per year. Parts with complex internal and external detail, superior finishes and thin wall capabilities can be produced, without the need for machining from solid.

By combining our non-ferrous investment casting technology with best practice CNC machining, Sylatech can overcome many of the constraints placed on engineering design whilst delivering the highest quality. Our unique manufacturing method affords greater benefits compared with other techniques.

The Sylatech Process

Process benefits

Why use the Sylatech casting process?

Reduce overall costs by Designing for Manufacture.

Simplify an assembly by combining a number of parts, eliminate joining processes and reducing the part count whilst improving the integrity of the finished product.

Reduce time to market through the use of Rapid Prototyping technology and obtain casting, machining, assembly and packaging from one source. Finished metal parts can be delivered from concept in under four weeks.

Design flexibility, with quick modifications to tooling that costs 90% less than for a pressure die casting, whilst maintaining economic batch quantities of up to 150,000 parts per annum.

High quality finish, detail and specification.

Able to ensure all casting has exacting dimensional accuracy due to our in-house CNC Machining capabilities.

Process capability

What the Sylatech casting process can deliver?

Thin walls as fine as 0.2 mm (0.008”), typically 1-3 mm (0.04” – 0.12”).

Light weight components, weighing as little as 1g can be produced using techniques to minimise material usage whilst retaining component integrity.

Ideally a maximum size of 190 mm x 160 mm x 160 mm (8” x 6” x 6”). A length of 250 mm (10”) is possible providing no other dimension exceeds 100mm (4”). Larger sizes can be considered on a case by case basis.

Complex detail on internal and external features. Zero draft angle.

Super-fine surfaces with 0.8 micrometres (32 micro inches) being the “as cast” finish.

Metals we cast

Metals CastTolerance
Aluminium Alloys+/- 0.1 per 20mm
Copper Alloys+/- 0.1 per 20mm


For full details of the capability of our casting process, download our