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Rapid Prototyping (RP) is a general name that encompasses numerous methods used to fabricate objects from CAD data. There are a number of different RP processes, and new developments are constantly being made.
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This family of casting processes is unique in that ceramic and plaster are used as molding media. These processes offer a high degree of precision in regard to dimensions, as well as excellent surface finishes.
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At least three families of molding and casting processes can be categorized as permanent mold processes. These include diecasting (high-pressure diecasting), low-pressure permanent mold casting and permanent mold casting. Unlike sand casting processes, in which a mold is destroyed after pouring to remove the casting, permanent mold casting uses the mold repeatedly.
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Fundamentally, a mold is produced by shaping a refractory material to form a cavity of a desired shape such that molten metal can be poured into the cavity. The mold cavity needs to retain its shape until the metal has solidified and the casting is removed. This sounds easy to accomplish, but depending on the choice of metal, certain characteristics are demanded of the mold.
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