Patterns are a critical component of the casting process which is why Wirco has always staffed and maintained an in-house pattern department. Pattern construction starts with Wirco’s process engineering group. Our skilled foundry engineers create and finalize solid model drawings of the pattern. The design will then be rigorously tested using MagmaSoft® simulation software to determine the best pattern configuration needed to achieve a high-quality casting. The approved model is transferred to the Avilla CNC pattern shop where it is converted to machine code using Surfcam® 3D Milling Software. Pattern machining is accomplished in-house using two large platform gantry style Haas CNC mills in addition to two standard CNC Haas mills. The Wirco pattern shop is climate-controlled and produces world-class patterns for both of our foundry locations. Wirco patterns are primarily cut from high-density polyurethane resin board, but occasionally patterns will also be constructed from wood, aluminum, and steel. A number of modern 3-D plastic printers are also employed for rapid pattern prototyping requests from Wirco customers. Final pattern prepping and repair operations are conducted by skilled craftsmen at the Wirco foundry in a newly constructed pattern staging area.
