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Consider metal core molding.

Most designers associate lost core molding solely with automotive air intake manifold. And while it is true that this process serves admirably in these applications, says CoreTech Assoc.'s Mark Battista, it has also piqued the interest of designers in other market segments where complex, hollow parts are the norm. "Although the process requires capital investment relative to part size, volumes, and the amount of automation involved, there are certain parts that cannot be made using any other process," Battista told IMM in a recent phone interview. "More designers in nonautomotive markets, especially sporting goods, general industry, and aerospace, are looking at what CoreTech trade named Metal Core Technology (MCT) to mold one-piece, internally complex hollow parts."

CoreTech offers a range of services, from initial components development and turnkey MCT workcells. Stand-alone core casting and melt-out equipment are available for those who wish to integrate production cells. Battista and partner Tom Kidd created CoreTech in 1995, following the acquisition of the division from former employer, Electrovert MDD, where they were responsible for business development and application engineering including production of the first high-volume U.S. plastic air intake manifold for GM's Northstar engine.

For the record, Battista refutes misconceptions about this process. "MCT is both cost-effective and environmentally safe. Tin-bismuth and other metal alloys cause no harm to operator, plant, or environment. Also, cores are completely recovered after they are melted out of the part, then reused continually without degradation. The only environmental issue is handling a small percentage of heat transfer fluid created during melt-out, and that is done effectively using equipment built into the workcell."

CoreTech staffers have found that OEMs and designers ask the same questions about MCT: Can it produce quality parts at a required rate? Can prototypes be evaluated before investing in new equipment? Are the plastic, metal, and other necessary materials available and proven? In all cases, Battista and company offer an unequivocal "yes."