Plaster Casting

Plaster casting is similar to the sand casting process, using a mixture of gypsum, strengthening compound, and water in place of the sand. The plaster pattern is typically coated with an anti-adhesive compound to prevent it from becoming stuck against the mold, and the plaster is capable of filling in any gaps around the mold. Once the plaster material has been used to cast the part, it usually cracks or forms defects, requiring it to be replaced with fresh material.

The advantages offered by plaster casting include:

• A very smooth surface finish.
• The ability to cast complex shapes with thin walls.
• The capacity for forming large parts with less expense than other processes, such as investment casting.
• A higher degree of dimensional accuracy than that of sand casting.

This process tends to be more expensive than most sand casting operations and may require frequent replacements of the plaster molding material. It is usually more effective and cost-efficient when the quality of the surface finish is an important requirement. Its application is generally limited to casting aluminum and copper-based alloys.

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