Frequently Asked Questions

Average tooling cost depends on part size and geometry; for detail information please call our Market Manager- Tim Connors at (518) 436-1263 ext.21

Depending on mold materials chosen and design, a typical mold may produce 1,000/parts/cavity before it needs replacement. However, small repairs can be made throughout its useful life.

Every mold is hand operated and assembled and disassembled by operators and not machines. This results in a high labor time per part. Our overhead structure is high because we sieve, mix & blend our raw material. Our kiln runs are costly due to the long run batch cycles we perform. This makes us most competitive on smaller "job-shop" type runs.

Yes. Once the tool is paid for and built, part prices become very attractive. History has shown that our combined tooling cost and part price is typically cheaper than just conventional manufactured part prices.

There really is no limit but currently we can make a 3,500lb. part. Most competitive in the 25 lb range.

Depending on tolerance requirements, we can make parts as small as a few ounces, approximately the size of a matchstick.

High Purity Aluminas, oxide bonded Silicon Carbides and Alumina/Silicon Carbide composites are the most common. We also make shapes of fused silica, zircon, and mullite/alumina composites. In addition, there are several developmental compositions available--please inquire.

High volumes are preferred, but we can make anywhere from 1 part a year or 10 parts a month with favorable costs.

.005" per inch. Part features and geometry must be considered. In some instances we can hold ± .002"

.060" where needed, but it is very dependent on part design and required tolerance.

We can go as thick as 8" in cross-section depending on geometry.

Alternative materials, tooling engineering, in-house productivity enhancements, reduction in overhead through volume and cellular manufacturing.

The part is typically no better than the mold, but a 64 rms finish can be achieved on internal diameters.

The part strength of Blasch shapes varies based upon composition. The strength can vary from flexural strength of 1,500 psi to well over 6,000 psi. The most widely used Blasch compositions, high aluminas, typically have flexural strengths well in excess of 3,500 psi.

Like most ceramics, Blasch shapes will fracture when dropped or abused. They are typically much stronger than castables that have been formed into shapes, however.

Yes. Although not recommended most secondaries can be done to Blasch parts (machining, grinding, coating, impregnating, etc.).

Yes. Especially with uniform wall sections. Plus it is very repeatable. Typical shrinkage is less than 0.5%.

No organic binder is present in Blasch shapes. When silica is used as a binder constituent, there is a small amount of crystalline or "free silica", which can be virtually, eliminated by mullitizing it with alumina at higher firing or use temperatures.

The Blasch process has the design advantage of casting very complex near net shape parts with excellent physical properties. Curved sections, threads, tapers, etc. can be cast. In other words, the Blasch Process is suited for high strength, complex geometries.

Yes. Once the tool is made any one of the Blasch numerous materials can be injected into the mold to produce different properties. Slight dimensional variations are possible however, based on mold allowance and material shrinkage.

Blasch parts have refractory-like properties, as they are to some extent porous (over 15% typically) and resist high temperatures. They are also chemical and wear resistant, and find applications in those areas as well. They are not fully dense like many "advanced ceramics". They do not have favorable electrical properties.

Part design engineering, system engineering (refractory and support equipment), post production processes, material testing, contract product development.