At Fowler & Holden, pattern making sits at the heart of everything we do. With over a century of experience, we know that high-quality castings start with precision patterns. In this guide, we explain the vital role of pattern making in foundry projects and how modern tools like CNC pattern making and CAD design make a difference.
What Is Pattern Making in a Foundry?
Pattern making is the process of creating the mould precursor – a physical model of the final part – that forms the cavity into which molten metal is poured. Patterns are critical to ensuring casting accuracy, repeatability, and structural integrity.
Each casting begins with a pattern. It dictates not only the shape of the finished part but also the surface finish, tolerances, and complexity the foundry can achieve.
The Role of Pattern Making in Foundry Projects
The role of pattern making in foundry production is foundational. Whether you’re producing ductile iron housings, drainage units, or heavy plant components, the pattern is where production quality begins.
Key Responsibilities of Pattern Making:
- Converting CAD drawings into physical tooling.
- Accounting for metal shrinkage during cooling.
- Creating core boxes for hollow components.
- Providing dimensional accuracy.
- Ensuring compatibility with moulding systems.
The better the pattern, the better the final casting.
From CAD File to Physical Pattern
In modern foundries, casting projects begin digitally. Engineers send a CAD file which is used to design a 3D model of the pattern. This can be made from wood, resin, foam, or metal depending on production needs.
We use a combination of manual craftsmanship and CNC pattern making to convert those designs into physical tooling. CNC machines allow for precise shaping, consistent quality, and reduced turnaround.
At Fowler & Holden, we accept most CAD file types and can assist with casting pattern design if you don’t have in-house resources.
Materials Used in Pattern Making
Different materials suit different casting jobs:
- Wood: Ideal for low-volume or prototype work.
- Resin: More durable and accurate, ideal for production.
- Metal: Used for high-run jobs or high-temperature alloys.
- Foam: Great for complex shapes or one-off investment casting.
We assess your job requirements to recommend the right tooling approach.
CNC Pattern Making: Precision and Repeatability
CNC pattern making brings several advantages to the process:
- Accuracy: Maintains exact tolerances from digital files.
- Repeatability: Enables consistent patterns across batches.
- Speed: Faster turnaround from file to production.
- Design Flexibility: Supports complex geometries.
This is especially useful when repeatable quality is essential, such as in OEM or safety-critical applications.
Importance of Foundry Tooling
Tooling refers to all equipment used to shape, hold, or form metal before and during the casting process. In pattern making, it includes:
- Patterns
- Core boxes
- Match plates
- Gating systems
Investing in the right foundry tooling ensures a smooth transition from design to finished casting. At Fowler & Holden, we offer both tooling design and maintenance, making us a one-stop solution for long-term supply needs.
FAQs
What is the purpose of pattern making in casting?
It creates the shape used to form mould cavities, ensuring accurate cast parts.
Do I need to provide a pattern, or can the foundry make one?
We can design and manufacture patterns based on your CAD files or reverse-engineer from samples.
How long does CNC pattern making take?
Lead times vary but are often faster than manual methods – typically 1-2 weeks depending on complexity.
What materials can patterns be made from?
Common materials include wood, resin, foam, and aluminium.
Can you modify an existing pattern?
Yes. We can adapt patterns for design changes or tolerance adjustments.
Why Work with Fowler & Holden for Pattern Making?
We bring together traditional craftsmanship and cutting-edge CNC technology to provide flexible, accurate, and reliable pattern making. Our in-house team collaborates with clients to ensure each pattern meets dimensional, structural, and production goals.
Whether you’re launching a new part, replacing legacy tooling, or troubleshooting casting issues, we support you from file to finished component.
For support with your pattern making and casting projects:
Contact us
Call: +44 (0)1472 355 316
Email: admin@fowlerandholden.co.uk
