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Pattern Making.

Built and Maintained In-House.

Complete patternmaking and tooling support to ensure repeatability, longevity, and production efficiency.

Excal’s in-house pattern shop gives customers a critical advantage: control. From new tooling builds to modification and repair of existing patterns, our experienced team ensures your molds are optimized for repeatable quality and long-term production reliability.

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Tool Design & Engineering

Why In-House Patternmaking Matters

Built for Repeatability and Production Longevity

Redundancy and in-house control reduce risk and improve lead-time reliability.

Tool Design & Engineering

We design new tooling for green sand and air-set processes, optimized for flow, gating, and repeatability.

Tooling Maintenance & Repair

We actively maintain customer-owned tooling to extend service life and protect your investment.

Modifications & Adaptations

Most existing tools can be modified for process improvements, alloy changes, or production scaling.

Urethane Corebox
Urethane Pattern

OUR PROCESS

From CAD to Casting

1

Tool Design & Engineering

We review your drawings and casting requirements — including solidification simulation to qualify designs and identify potential issues prior to building tooling — to determine pattern strategy.

2

Pattern Construction

Built using wood, urethane, aluminum, or composite materials depending on volume and complexity.

3

Gating & Core Integration

Patterns engineered using proven solidification simulation for efficient fill and minimal defect risk.

4

Ongoing Maintenance

We service and store tooling to ensure readiness for repeat programs.

FAQ — PATTERNMAKING

Your Questions, Our Answers

Yes. Excal stores customer-owned tooling in our facility and maintains it between production runs so it’s ready when you need it.

In most cases, yes. Our pattern shop can adapt existing tooling for process changes, alloy substitutions, or volume scaling — often without requiring new tooling investment.

We build patterns in wood, urethane, aluminum, and composite materials. The right choice depends on your production volume, part complexity, and expected tooling life.

Yes. We accept 3D CAD files and use them directly in our pattern design, tooling layout, solidification analysis, and engineering processes, reducing lead time on new tooling programs.

Ready to Start a New Tooling Program?

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