Category: Precision Casting, rapid prototype

Slashing Lead Times with the Best Rapid Prototyping Technology for Investment Casting

Lestercast – Reinvesting in the Latest Rapid Prototyping Technology…

At Lestercast, we don’t just keep pace with change – we drive it. By reinvesting in cutting-edge technology and pioneering new production methods, we’ve transformed investment casting into a faster, more flexible, and more competitive process than ever before.

Traditionally, investment casting has meant longer lead times when compared to sand casting manufacturing routes. Today, thanks to advanced workflows, proprietary process developments, and rapid prototyping, parts that once took weeks can now be delivered in days – without any compromise on precision, performance, or quality.

While 3D metal printing has captured attention across the industry, our advancements demonstrate that investment casting remains one of the most efficient, scalable, and cost-effective solutions for producing complex, high-strength components. We deliver the speed and agility of additive manufacturing, combined with the proven reliability and superior surface finish of precision casting.

We are proud to announce two major breakthroughs:

  • Lestercast have invested in the next-generation 3D wax printing technology – the fastest available and the first machine of its kind in a European Investment Casting facility, is now a dedicated rapid prototyping route to reduce lead times and increase productivity. Castings produced from newly printed 3d wax patterns now have a surface finish comparable to castings from traditional tooling.

 

  • Lestercast have developed a brand-new drying chamber – engineered to dramatically compress production schedules while maintaining Lestercast’s renowned standards of consistency and quality. The new process shortens the ceramic mould manufacturing time by 70%.

 

Together, these innovations empower our customers with rapid turnaround, dependable repeatability, and exceptional results.

Lestercast isn’t just preparing for the future of manufacturing — we’re defining it.

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Lestercast Investment Casting Vs 3D Metal Printing

FACTOR

LESTERCAST INVESTMENT CASTING

3D METAL PRINTING

Production Speed

Lead times dramatically reduced using the latest 3D wax printers.

Fast for prototypes and small runs, but slower for larger or more complex builds.

Scalability

Highly scalable - ideal for small batches through to high-volume production.

Limited scalability - best suited for low-volume or one-off parts.

Component Size

Flexible, capable of producing very small to very large parts.

Restricted by printer build chamber size.

Surface Finish

Excellent surface finish, minimal post-processing required.

Rougher surface, often needs machining or finishing.

Material Range

Wide range of alloys (steels, aluminium, nickel, cobalt, bronze, etc).

Growing but still limited selection of printable metal powders.

Microstructure and Mechanical Properties

Only certain alloys require Heat Treatment to achieve desired properties.

Most printed metal parts require multi-stage Heat Treatment to achieve the minimum mechanical properties for the alloy.

Design Freedom

Very high complexity achievable, especially with wax pattern prototyping.

Exceptional for lattice structures and internal geometries.

Cost Effectiveness

Cost-efficient for both prototyping and volume production.

Economical for one-offs but expensive at higher volumes.

Reliability and Consistency

Proven, repeatable, industry-trusted process.

Variation possible between builds, especially across machines. Large temperature differentials during printing cause internal stresses.