Pattern Shop

Operating within İstikamet Döküm, the Pattern Shop and Mold Design Department constitutes the first and most critical stage of casting quality. In order to support our company's annual 40.000 ton casting capacity for sectors requiring high precision such as automotive, agricultural machinery, infrastructure elements, and offshore wind energy, pattern design and production are carried out entirely with a computer-aided advanced engineering infrastructure.

1. CAD/CAM Design and MagmaSoft® Simulation Integration

During the implementation process of a new project in our pattern shop, all APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process) requirements are fully implemented.

• Casting Simulation: Developed 3D designs are tested with MagmaSoft® casting simulation software, verifying the flow velocity of liquid metal inside the mold, solidification curves, hot spot distributions, and riser placements prior to casting. Thus, casting defects such as porosity and shrinkage are minimized to zero, optimizing pattern design.

2. High-Precision CNC Pattern Manufacturing

The 3D CAD data approved by our engineering department is machined from aluminum, steel, araldite (resin), or wood materials according to the requirements of the foundry molding lines. Our modern CNC machining centers used in pattern manufacturing are as follows:

• Mazak Variaxis i-800T (5-Axis Machining Center): With an 800 mm maximum workpiece diameter, 500 mm maximum workpiece height, and 0.0001° indexing precision, it machines motor blocks and planet carrier patterns with the most complex geometries at micron-level tolerances.
• Mazak HCN 8800 (4-Axis Horizontal Machining Center): With a 1450 mm x 1450 mm maximum workpiece size capacity and 37.0 kW motor power, it has the ability to machine large-scale heavy industrial casting molds at high speed.
• Ares and Avea CNC Machining Centers (3-Axis): Allows for the serial and precise production of pattern plates of different sizes.

3. Full Compatibility with Molding Lines and Pattern Technology

The produced pattern plates (pattern plates) are designed in full compatibility with the specific technical dimensions of the automatic and manual molding lines in our foundry:

• RWS Automatic Horizontal Molding Line: High-strength pattern plates are designed to fit 1000 x 1100 x 200 x 200 mm flask dimensions and a production capacity of 100 molds per hour.
• HWS Automatic Horizontal Molding Line: Integration of double-sided pattern plates capable of molding 100 molds per hour in 1000 x 1100 x 250 x 250 mm flask dimensions is carried out.
• Furan Resin Molding System: Custom split and core-assembly pattern sets are prepared for large parts that can be cast up to a weight of 1500 kg without size limitations.

4. Rich Pattern Inventory Compliant with Standards and Traceability

İstikamet Döküm has one of Turkey's richest ready pattern libraries for manhole covers, rainwater grates, and polymer concrete drainage channels compliant with TS EN 124-2 and TS EN 1433 standards.

• Systematic Storage and Maintenance: All patterns, whether produced in our pattern shop or delivered by our customers, are preserved in address-defined modern steel rack systems protected against moisture, temperature changes, and physical impacts.
• ERP Traceability: Every pattern plate is digitally tracked through the ERP system in line with its casting lifespan, revision history, and maintenance periods, ensuring uninterrupted and sustainable production quality.