Investment casting also called lost wax casting, is one of our core competencies. Investment casting/lost wax casting is a manufacturing process that is used to create complex shapes that may have thin walls in a quick and cost effective way. As the name “casting” implies it is a process of pouring molten liquid metal into a mold. The “lost wax” term comes from the use of a wax master to create a mold. The wax is melted out of the mold once the ceramic coating that forms the mold is dry.
We always achieve high quality results by using Toyota Production System (TPS), Pre Production Approval Procedure (PPAP) and Process Control Plan (PCP). These procedures are used to evaluate and eliminate any variation in the process, and guarantee the quality of the final product. Our commitment to strictly follow these quality management procedures is more than requirements on ISO9001 quality system. We can offer both low volume and high volume production quantities.
Pre-Production samples/prototypes
We are able to provide samples without having to invest in the tooling for making an injection mould tool for the wax master. We are able to 3d print a small number of wax masters, from which we can provide investment cast parts, which can be used to provide samples for testing and evaluation during the design phase. We can do this for both steel and titanium parts. We can also HIP treat the parts in small volume, the samples are truly representative of production parts.
Materials Available
Stainless steel in many alloys including but not limited to: 303, 17-4, 420, 430,440, Tool Steels and Titanium alloys, Like Ti6V4AL. Material from every pour is tested using OES technology this a standard part of the process. All test results are well documented and traceable. The correct material choice will depends upon the customer’s application, assistance available upon request. Post heat treatment/hardening is done on site in a controlled environment producing parts within the hardness range from 28 up to 60 HRC ( Hardness Rockwell scale C ).
Secondary Operation
After casting the parts may need to be machined to achieve some precise dimensions, threads may also need to be added. The surface finish may need to be improved for parts with visual surfaces. A variety of finishes including high gloss polishing, sand blasting, brushed finish, painting, nickel or chrome plating and Physical Vapor Deposition (PVD) are all done on site to the highest possible standards under controlled processes. In addition, the physical properties may need to be improved. This can been achieved by using Hot Isostatic Processing, this process improves the density of the casting and is recommended for parts that are designed for use in demanding situations.
Lead-Time
Lead-Time Of Investment Casting Mold: On average we can design and machine a mold in 15 days! Notwithstanding, the complexity of the product plays a part. Lead-Time Of Samples: Additional 2 weeks to provide the first final samples. Production lead-time: normally 500pcs to 2000pcs per day per production line. Again, determined by complexity of product.
Quality Assurance
Investment casting and the secondary operations can be a very long process and also a labor intensive job. Investment casting has the potential for process variations. To ensure consistency, we apply auto industry quality procedures including:
Process Control Plan (PCP): Defines the process flow and determines the detailed inspection points of each process. We use this procedure together with working instructions to make sure every operator and inspector clearly understands what should be done and when. Quality management of the process results in a defect free product.
Pre Production Approval Procedure (PPAP): Used on all projects in our company. This procedure is to make sure all needed samples and documents are available. It’s also used to evaluate all key process by doing analysis of the collected data.
Toyota Production System (TPS): Used to define the layout of each production line and also define how a part goes though the whole process to improve the production efficiency. Also it clearly defines what each process doing.
Material Testing: Each batch of material is tested by an optical emission spectrometer right before casting to guarantee the material content is within the correct range. This process is part of our standard process control plan and results are well documented.
Production Development Cycle
Once we receive an order we follow a strict procedure that has proved to be effective. The design engineers evaluate the product and design the mold.
Tool Making: The mold for making the wax master is made using the latest CAD/CAM technology and equipment including 5 axis DMG CNC milling machines.
Mold Trial: The mold is injected with wax to create the initial wax masters. These parts are fully inspected using optical measuring equipment by Metrology experts. Modifications may need to be made for very complex parts. The cycle continues until the wax molding is within acceptable parameters. A sample run of wax masters will be molded for next round of trials.
Making The "Shell" Or Mold: The master craftsman will oversee and document the first shell making process. Once the mold is ready, the project will move progressively through the facility, being processed by the technical leaders in each department, all process parameters being fully documented. When the first batch is complete, they are fully inspected and all data collected is analysed, any issues are addressed in team meetings and remedial action is designed and implemented as required. Then the process is repeated until defect free parts are produced.
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In the heart of Brisbane's vibrant southeastern suburbs lies Haigslea, a thriving community that benefits from COLETEK's commitment to local businesses and entrepreneurs.
As a trusted Australian company with extensive experience serving Haigslea, Brisbane, Queensland, Australia, we understand the unique needs of the area. Our reputation is built on a foundation of trust, innovation, and genuine concern for the well-being of our clients. Whether you're an established business or an ambitious startup, COLETEK is dedicated to helping local entrepreneurs like yourself succeed.National in scope yet locally attuned, we've had the privilege of working with numerous Haigslea businesses across a broad range of industries. Our experts boast a deep understanding of the digital landscape, empowering local companies to compete effectively and adapt swiftly to changing market conditions.
At COLETEK, we value long-term partnerships that foster growth, innovation, and job creation in the Haigslea region. By leveraging our expertise, businesses like yours can stay ahead of the curve, drive revenue growth, and maintain a competitive edge within their chosen markets.So why turn to a company located elsewhere when you have a trusted, nationally recognized player right in your own backyard? COLETEK is committed to supporting Haigslea's diverse business community, providing tailored solutions that address the unique challenges faced by local firms. We're proud to offer:
...unwavering commitment to our clients, ensuring every interaction leaves a lasting positive impression. ...innovative approaches that drive progress and boost competitiveness for Haigslea businesses. ...personalized support, taking the time to understand your specific needs and concerns.Take the first step towards elevating your business in Haigslea today. By partnering with COLETEK, you'll experience the difference that comes from working with a trusted Australian company deeply rooted in the local community.
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Highly recommended for COLETEK's service! Reasonable price and express service! We have two back up external hard drives at home and for some reason both of them were corrupted (later found out it’s due to some sort of electrical surge??). Both drives contained over 10 years of valuable technical works, numerous photos from our pre-kids travel days, as well as photos and videos of our first born! We tried another company but only recovered around 55% of the data and it costed a FORTUNE! Contacted COLETEK, explained the problems and received my recovered data within 14 days of initial contact (it wasn’t an urgent case). I was over the moon when I was able to locate a technical piece of work that I’ve done 15 years ago, and of course videos and photos of our first born.
I had an external hard drive containing valuable data that quit working. I thought everything was lost. I used the services of COLETEK to restore the contents of my drive and i was able to retrieve everything. I would not hesitate to use COLETEK for hard drive recovery.
After approaching COLETEK with a few sketches of a plumbing tool I had in mind Luke and I immediately bounced a few ideas around. Leaving things with Luke he quickly produced some 3D images and ideas we subsequently used. Before long COLETEK produced an operational 3D printed prototype of the tool. I was then able to use this prototype to seek funding for further research and development.
We used COLETEK on a small project involving mechanical and electronic design aspects as well as software development. COLETEK understood our requirements at the outset and worked to accommodate our needs. The whole process was professionally conducted and we highly recommend COLETEK
We recently engaged the services of COLETEK to perform some penetration testing on our systems. We found Luke flexible and accommodating with our specific needs. Luke provide what we needed to show our clients our security measures with our systems. I would have no hesitation in recommending Luke.
We engaged COLETEK to conduct a series of research projects on robotics and we very pleased with their technical skill, creative thinking and hard work. If you need to prototype a complex technical idea, they are a great partner to work with.
We met with Luke Cole from COLETEK and very quickly realised that he was very knowledgeable in robotics and prototyping. What separates his company from the rest, is that he had a unique value proposition - COLETEK offers a tele-operated / robotic unit for rent and with the flexibility to be modified to build proof-of-concepts. That unit lowered both the cost and time for us to produce a video showing a very challenging concept. In general COLETEK's service was great value. We would recommend them - they will get it done.
COLETEK has assisted on a variety of last-minute 3d printing overflow tasks for various projects. I've always found them to be very responsive to my needs and turned around urgent work in shortest possible time frame. I wouldn't hesitate to use or recommend COLETEK for any future design and/or 3d printing requirements.
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We worked with Luke from COLETEK to develop a prototype for a new venture. Luke was able to give us practical advice on how to execute the project inline with our budget that was super useful. What has been endearing, is that even after the build was complete, Luke continues to touch base with us offering help to keep the momentum of the project going forward.
I consulted COLETEK for some work, commencing in 2014, and haven’t looked back. The project was very important to me, and COLETEK not only saw that but exuded sincere enthusiasm about the project; they are attentive, and thorough in their research and development service. They are a wealth of information and advice, for many aspects of the entire engineering and commercialization space, and this has been invaluable to me. I look forward to continuing work with them long into the future!
I would thoroughly recommend COLETEK they provided me with excellent feedback and engineering knowledge with regards to our idea. They also have continued to help us with what direction we should take and introduced us to other professionals that have also guided us. I suggest anyone who has been thinking of something they would like to pursue should contact them to get the most realistic approach of making it successful.
In the development of our new product Smart Syphon we had a tight deadline to launch the commercial version of our product and experienced some issues with our drawings. Luke and his team dealt with the issues, worked through the week-end and delivered a quality outcome on time.
Luke from COLETEK has assisted us on a number of occasions and has always been helpful, courteous and understanding of our needs. There was an instance when timing was of the essence and Luke was able to prioritise our job to ensure we weren't affecting our customers in a negative way. He is highly recommended.
Founded in 2001, we are a multiple award winning, highly experienced multidisciplinary company specialising in lean product development through rapid prototyping - transforming ideas from concept to life. Our industry-leading team combines deep expertise, cutting-edge technology, and advanced equipment to validate emerging ideas—transforming them into market-ready hardware and software solutions.
Our experience dates back to the 1990s with ANU "Robotics Systems Lab", CSIRO, NICTA (aka Data61), Seeing Machines, Location Aware Technologies, and Hemisphere GPS (aka BEELINE). For over 10 years now, we've been focused on validating R&D and taking ideas to commercialisation.
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