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Investment Casting Services

Fathom offers metal casting prototype services in a variety of materials including magnesium, aluminum, zinc, and bronze, which are created with a plaster, sand, investment or permanent molding process. 

The Process

1. A master model is created from the master mold
2. The master molds are used to generate plaster molds
3. The mold is left to dry (typically 3-5 days)
4. The metal is poured into the plaster mold
5. The final product is cleaned and prepped for shipping or machining

Wax is injected into an aluminum die to produce a pattern that is an exact replica of the part to be produced. For every casting, a wax pattern must be manufactured. The patterns are clustered around a coated sprue and repeatedly dipped into an agitated vat of ceramic and allowed to dry. After a shell thickness of approximately 3/16″ has been built, the molds are dewaxed by either flash firing at high heat (1,400° F.) or autoclaving (pressure and steam). The hollow shells are then preheated to 800-2,000° F, depending on the alloy to be poured. The molten metal is immediately cast into the hot shell. After the metal parts have cooled, the ceramic is vibrated, blasted off and discarded. The balance of the cleaning operations (cut off, grind, heat treat, straightening & blast) are straightforward and quite similar to the other casting processes.



Low Alloy Steels Investment Castings Martensitic Stainless Steel Investment Castings Austenitic Stainless Steel Investment Castings Duplex Stainless Steel Investment Castings Ferritic Stainless Steel Investment Castings Tool Steel Investment Castings
1020 410 303 ASTM 890 Grade 4A 409 A2
1045 416 304, 304L 430 A6
1050 420 316, 316L 436 D2
1095 431 316 Non-Mag 446 D5
4130 15-5PH CF-8, CF-3 L6
4140 17-4PH CF-8M, CF3M M2
4150 440A 330 M52
4340 440C 347 O1
6150 CA-6NM 20-CB3 S5
8620 Alloy 20, CN-7M S7
8650 CF10-SMnN


Copper Base Alloys Investment Castings Nickel Base Alloys Investment Castings Cobalt Base Alloys Investment Castings Aluminum Investment Castings
CDA 872 NI-B CoAlloy 3 356
CDA 875 NI-C CoAlloy 6
CDA 876 NI-X
CDA 903 NI-625

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day

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30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks

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3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

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Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.