ISO 9001:2015 and AS9100:2016 (Rev. D) Certified

Sycast, Inc is a Small Business Concern, Cage Code 7EJW9

Sycast Inc.

148 Bartholomew Ave 

Hartford, CT 06106

+1 860.308.2122

M-Fri 830am-5pm EST


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  • Rapid delivery of castings, typically in 1-2 weeks
  • Excellent surface finish, and detail resolution
  • Highest accuracy castings
  • Lowest tooling cost of traditional casting methods
  • No VOCs, hazardous material or waste. 

Pictured Above:  A thin-wall aluminum ram tube casting next to the bottom half of the plaster mold in which it is cast (plaster core assembled in place also pictured).

Pictured Above:  A thin-wall zinc chassis casting required alpha testing before the OEM invested in diecast tooling.

Plaster Mold Casting

Plaster molds are used to produce high-accuracy, high detail castings in any non-ferrous alloy.  Plaster mold castings can be thin-wall (down to .010" locally) and exhibit similar smoothness and accuracy as die castings. Typical applications for plaster mold casting are:

  • Diecasting prototypes & bridge-to-production requirements
  • Short-run production castings
  • Thinwall castings of any geometry (down to .010" locally)
  • Complex casting geometries with tight tolerances
  • Waveguides, Impellors, Heatsinks, Housings and Bezels


Plaster Mold Casting Process

Foundry tools are designed in CAD and subsequently cnc-machined, typically from high-density urethane or aluminum.  Alternately, foundry tools can be produced directly from Rapid Prototype models, such as SLAs.


A batch-mixed gypsum composite slurry is poured into flasks containing the foundry tools. After the slurry has set, the hardened plaster molds are stripped from the foundry tools. The plaster molds are then baked, assembled and are ready for metal to be cast.

Plaster Mold Castings

Plas​ter Mold Castings