PIAD is the leading copper-based permanent mold foundry in the United States. Starting as a joint venture between the inventor of the chill cast process and an American manufacturing company, PIAD produces high-quality permanent molds made of elemental metal alloys rather than traditional sand molds. Since 1967, PIAD remains focused on delivering the permanent mold industry's best in quality, performance, and overall cost-savings.

PIAD produces precision castings by the chill-cast permanent-mold process.

Whereby, molten materials are poured into a precision metal die.  The molds which are chilled, in a liquid bath, between cycles, rapidly draw the heat out of the molten material to produce a component with high integrity and dense grain structure.

It is a one-step process, which significantly reduces labor and overhead costs. Queue times are shortened because there is no waiting or bottlenecks between required operations and steps.

The components go from liquid material, to casting, cool down, and cleaning operations within hours. Compared to what could take weeks with other processes.

PIAD alloys range from pure electrolytic copper, chromium-copper, brass, aluminum-bronze, tin-bronze, and ZA73. All alloys have been developed for the process with specifications much tighter than commercial grade alloys. The alloys all start with pure, virgin materials. No scrap is ever used. The alloys provide a wide range of properties to meet most engineering requirements from electrical conductivity of 98%minimum to tensile strength in excess of 115,000 pounds per square inch.

Components can be produced from ounces to 35 lbs., with up to 18 linear inches in size.

Most any geometry can be accommodated. PIAD sales and engineering will help to design products to fit all functional requirements yet provide all the value and advantages the process can offer.

The size and complexity of a component, somewhat, dictate the achievable tolerances. Normal tolerances are +-010 for 2 inches and +-002 for each additional inch. Special and premium tolerances are achievable in selected areas by pouring procedures or fixturing of components upon removal from the mold.

PIAD provides completely finished components in instances where secondary operations cannot be eliminated

Because the castings are formed in a precision die with closely machined surfaces, inherently, the costing surface is smooth and brightly metallic. Secondary surfaces are easily achievable by sand blasting, polishing, plating or painting.

Cast surface chart

The “price” of a PIAD casting may appear to be more expensive than other methods. It is important that the price be compared to the actual “cost” of a component. The higher price should be evaluated against the turning, milling pricing and grinding operations that have been eliminated or reduced by the near net shape capabilities of the process.

Usage ranges of l00 to 100,000 pieces per year will comply with the process requirements. However, the economics of the total savings and tooling expenditure dictate the actual range of use.

As previously mentioned, the molds are highly precision metal dies, manufactured from a variety of materials to optimize the operation and life of the tooling. Customers pay only for the initial mold and any modifications requested by the customer. PIAD maintains and replaces tooling, as required.

Mold pricing is derived from the size and complexity of the component. Most mold costs, range between $2000 and $8000. The average cost is approximately $3500.

Generally tooling and samples require 10-12 weeks and 3-4 weeks for production. This is negotiable depending on workloads and backlogs at any particular time.