Foundry Pattern Shop & CNC Pattern Milling
Pattern-making is a critical step in producing high-quality castings at Knights Foundry. The shop uses both conventional and CNC methods, so patterns can be made for one-off work and for repeat production.
Traditional & CNC Pattern-Making
In conventional pattern-making, skilled craftsmen manually shape wood, resin or metal. This method is well suited to custom, low-volume or highly detailed work.
CNC pattern-making uses CAD/CAM software and computer-controlled machining to turn 3D models into accurate, repeatable patterns. It holds tight tolerances, shortens lead times and reduces material waste, which makes it ideal for high-volume or complex geometries.
CNC Pattern Milling Process
Knights Foundry uses a Unicam CNC router with a 4 m x 2 m x 400 mm bed to manufacture high-precision casting patterns. The process starts with 3D CAD modelling, then designs are imported into CAM software to generate tool paths.
The CNC router machines wood, resin board or tooling foam with multi-axis cutting, producing fine detail to tight tolerances. The large bed allows more than one pattern to be produced in a single setup, which improves efficiency and reduces changeover time.
High-speed spindles and controlled boundaries help hold accuracy. Once milled, patterns are finished and inspected to the foundry’s standards before they are used in casting.
Materials Used for Pattern-Making
| Material | Advantages |
|---|---|
| Meranti Timber |
Lightweight yet strong, easy to machine and handle. Suitable for manual and CNC machining with a smooth finish. Cost-effective for one-off or low-production patterns. Can be sealed and coated to improve durability. |
| Plywood |
Offers good stability with minimal warping. Great for large or multi-piece patterns. Compatible with both hand tools and CNC machining. Stronger than softwood yet lightweight. |
| Resin (Polyurethane & Epoxy) |
High durability and wear-resistant, ideal for high-volume production. Excellent dimensional stability for precision patterns. Machinable with tight tolerances and smooth finishes. Moisture- and chemical-resistant. |
| Necuron (High-Density Urethane) |
Stable and precise, well suited to CNC machining. Available in multiple densities for various casting needs. Minimal expansion, ensuring accuracy. Easy to shape, sand and finish. |
| Plastics (ABS, HDPE, Acrylic) |
Lightweight and machinable. Impact-resistant and durable. Moisture- and corrosion-resistant. Certain plastics offer heat resistance. |
Accurate Patterns for Repeatable Castings
By utilising a variety of materials such as meranti, plywood, resin, Necuron and plastics, Knights Foundry ensures each pattern is crafted with the highest level of precision, durability and efficiency to meet customer-specific casting requirements.