All-ceramic investment casting process

In the Ceracore® SHELF process, we produce core packages with all-ceramic molds and cores. Our automated production lines enable us to respond quickly, cost-effectively and flexibly to your product requirements.

Compared to the traditional wax melting-out process, the Ceracore® SHELF process impresses with a lead time of just 2 to 3 working days for mold production and casting.

Ceracore® SHELF – overview

  • We use Ceracore® SHELF to produce investment castings
  • In contrast to the traditional lost wax process, we produce the all-ceramic molds with plastic tools
  • We don’t use wax for the production of the molds
  • After drying, the cores are fired and assembled into a ready-to-cast mold package
  • Casting is realized in the preheated mold
  • The surface finish and dimensional tolerances are identical to the lost wax process


  • Mold production is significantly faster compared to traditional investment casting
  • Production of small and medium batch sizes is possible
  • No wax is needed
  • Production of accurate and stable casting molds
  • Production of large-volume investment castings is possible


The best of both worlds – sand casting process with ceramic inlays

In the Ceracore® HYBRID process, we produce hybrid core packages. Contours with regular requirements for accuracy and surface quality are made from core sand, while highly complex sub-areas with high surface qualities are made from ceramic cores. Components are often manufactured entirely by investment casting, although only small areas of the component require the high surface properties of investment casting.

Ceracore® HYBRID – overview

  • A combined process of sand casting and ceramic casting
  • New innovative process without wax cores
  • Different surface qualititys in one casting part are possible
  • Rapid production readiness due to modular system
  • Low tooling costs
  • Complex components from 500 grams to 100 kilos
  • Sand cores or ceramic cores can be used
  • Ceramic cores can be used cold or hot
  • Iron casting and steel casting can be produced
  • For medium and large series
  • From prototype to ready-to-use assemblies
  • Highly automated
  • Castings measured and tested during serial production
  • Pre-machining and finishing possible in one process loop


  • Combination of investment casting and sand casting surfaces
  • Mold production is highly automated
  • Thin contours and wall thicknesses through use of preheated ceramic cores
  • Short set-up times (<10 minutes)
  • Manual casting also used in serial production
  • Fast for geometric changes or adjustments
  • Complex geometries with high core intensity
  • Versatile materials from a single process
  • High surface quality due to ceramic mold
  • Raw castings in <10 days throughput time
  • Low initial costs by using tools made of plastic
  • Cost-effective production
  • All series sizes are possible, suitable for large quantities
  • Expandable with mechanical processing
  • High precision


This is where investment casting reaches its limits…

This is where investment casting reaches its limits… In the Exacast® process, components that cannot be produced by investment casting due to their high weight, large dimensions or thin wall thickness are manufactured fully ceramic in the core package. In this process, ceramic-coated refractory molds are used in which ceramic cores are inserted as required.

Things to know about investment casting

The investment casting process is the oldest known casting process in the world and was already used in the time around 3,000 BC. In the 2nd half of the 18th century, and with the beginning of the industrialization, a strong focus was put on the investment casting process. The increasing demand, accompanied by technical innovations, led to the breakthrough of this historically evolved process, which today is also known as lost wax casting.

Investment casting is an innovative casting process used for the production of accurate and detailed cast products. The process is also known as precision casting. In investment casting, mostly metallic materials are cast. Steel investment casting, with its large number of different alloys, is most frequently used in high-tech industries. These industries include general mechanical and plant engineering, turbine construction, trucks, the food industry, pharmaceuticals and medical technology, and many others.

The investment casting process enables us to provide castings with smallest tolerances. For very small sizes, precision of 0.1 mm and less is possible. If higher accuracies or tighter tolerances are needed for the application, the investment castings are further specified and refined by subsequent mechanical processing. Coating is possible in a wide variety of finishes.

Thanks to the investment casting method, the ceramic process gives significant scope in the area of product design and material selection. Wolfensberger AG designs optimal castings according to its customers’ needs and produces them according to their ideas and required criteria.

Compared to other casting processes, investment casting also has advantages in the optimization and reduction of the weight of products, an improvement in the surface quality and the appearance of visible components with maximum efficiency and conservation of resources. – and it is environmentally friendly at the same time. Even the integration of accompanying functions or the substitution of components from other processes is frequently applied in investment casting.

To master the investment casting process, the development partner needs the required know-how. Wolfensberger AG offers many possibilities already in the prototype phase and in the starting phase of series production and adapts to the needs of its globally operating customers. The focus is on the feasibility of investment casting products at cost-effective conditions.

With its investment castings, Wolfensberger AG provides international industries with high-quality cast steel components.

Ceracore Shelf, Ceracore Hybrid and Exacast are used in numerous castings. Here you will find a selection of previous applications of the processes:

  • Exhaust manifold
  • Exhaust pipe
  • Adapter plate
  • Stopper
  • Connector housing
  • Support
  • Spacing ring
  • Outer ring
  • Outlet housing
  • Brake disc
  • Brake carrier
  • Damper bracket
  • Cover
  • Pressure plate
  • Nozzle ring
  • Inlet housing
  • Fitting
  • Flange
  • Guide
  • Housing
  • Housing cover
  • Articulated lever
  • Gearbox housing
  • Gear carrier
  • Base body
  • Cast hub
  • Retainer
  • Heat shield
  • Housing
  • Inner housing
  • Cap
  • Valve cone
  • Valve cone housing
  • Chain guide
  • Chain link
  • Rocker arm
  • Valve disc
  • Clamping jaw
  • Clamping ring
  • Clamp
  • Latch
  • Node element
  • Bracket
  • Elbow
  • Coupling
  • Coupling shell
  • Crank
  • Labyrinth disk
  • Bearing
  • Bearing housing
  • Bearing bracket
  • Bearing body
  • Impeller
  • Guide rail
  • Grinding disk
  • Shell segment
  • Machine column
  • Machine table
  • Measuring head
  • Measuring angle
  • Carrier
  • Motor suspension
  • Motor flange
  • Mouthpiece
  • Camshaft
  • Nozzle
  • Pelton runner
  • Pelton blade
  • Piston
  • Planetary carrier
  • Propeller blade
  • Pump impeller
  • Pump rotor
  • Wheel head
  • Wheel carrier
  • Friction disk
  • Pipe bend
  • Rotor
  • Rotor half
  • Suction valve cover
  • Shift lever
  • Blade
  • Worm
  • Secondary gear
  • Sensor housing
  • Clamping jaws
  • Clamping lever
  • Stator
  • Adjusting lever
  • Protection plate
  • Beam
  • Crossbeam
  • Turbine wheel
  • Turbine diffuser
  • Turbine housing
  • Turbine wheel
  • Turbocharger
  • Turbine blade
  • Valve
  • Valve cover
  • Valve cone
  • Compressor housing
  • Wear plate
  • Vertical slide
  • Gear wheel
  • Centrifuge
  • Feed hopper
  • Cylinder cover
  • Cylinder joint

Get your non-binding offer now

Tell us a little bit about your plans and we will get back to you as soon as possible.

    (max. 5 MB)