1.
Introduction to Pattern Making
1.1 What is Casting?
Casting is a manufacturing process where molten metal is poured into a mould cavity of
the desired shape and allowed to solidify.
The solidified object, known as casting, is then removed for further processing.
1.2 What is a Pattern?
A pattern is a replica or prototype of the casting to be made.
It forms the mould cavity when pressed or packed into moulding sand.
In simple terms:
Pattern = Model used to form mould cavity for casting.
1.3 Why Pattern Making is Important
• Determines the accuracy, surface finish, and strength of the casting.
• Reduces defects and rejection rates.
• Essential for mass production and reproducibility.
2. Functions of a Pattern
1. Form mould cavity in the sand.
2. Provide shape and size identical to final casting (with allowances).
3. Help in positioning cores for hollow sections.
4. Incorporate gating and riser system if required.
5. Facilitate easy removal from sand without damaging the mould.
3. Pattern Materials (Detailed)
Different materials are used based on quantity, accuracy, and casting metal.
Material Properties Advantages Disadvantages Applications
Absorbs moisture, Small batch
Wood (Teak, Light, easy to Easily worked,
warps, wears work,
Mahogany, Pine) shape, cheap low cost
quickly prototypes
Metal
Strong, hard, Long life, Large batch &
(Aluminium, Heavy, costly
durable accurate, reusable mass production
Brass, CI, Steel)
Material Properties Advantages Disadvantages Applications
Precision
Plaster of Paris Brittle, smooth Intricate details, Fragile, low
patterns,
(POP) surface fine finish strength
prototypes
Plastic
Rigid, smooth, Moisture-proof, Costly, difficult to Medium-scale
(Polyurethane,
resistant durable repair production
Epoxy)
Soft, melts Perfect surface, Investment
Wax One-time use
easily easy removal casting
Directly used in
Polystyrene Lightweight, mould Lost foam
Single use only
(Foam) easy to shape (evaporative casting
casting)
4. Types of Patterns (With Detailed Explanation)
4.1 Single-Piece (Solid) Pattern
• Simplest type — made in one piece.
• Used for small, simple castings.
Example: Bushes, simple brackets.
Diagram Idea: A rectangular block used to form a simple cavity.
4.2 Split (Two-Piece) Pattern
• Split along the parting line into two halves:
o Cope (upper half)
o Drag (lower half)
• Dowels used for proper alignment.
Example: Engine cover, pump housing.
4.3 Match Plate Pattern
• Two halves mounted on either side of a metal plate.
• High dimensional accuracy.
• Used in machine moulding and mass production.
Example: Automotive components.
Diagram Idea: Pattern halves attached to both sides of a plate with gating system.
4.4 Loose-Piece Pattern
• Detachable parts to aid removal from mould.
• Useful for undercuts or projections.
Example: Valve bodies, elbows.
4.5 Sweep Pattern
• A wooden template rotated around a vertical axis to produce a symmetrical cavity.
• Economical for large circular jobs.
Example: Pipes, large bells, manhole covers.
Diagram: Template sweeping around axis to create circular mould shape.
4.6 Skeleton Pattern
• Framework structure of the shape of casting.
• Mould cavity completed by filling sand within the skeleton.
Example: Large and simple castings like tanks, pipes.
4.7 Gated Pattern
• Pattern includes built-in runners and gates.
• Saves mould preparation time.
Example: Multiple small castings in one mould (e.g., nuts, bolts).
4.8 Segmental Pattern
• A section of a circular pattern used for large circular objects.
Example: Flywheels, pulleys.
5. Core and Core Prints
5.1 Core
• A sand structure used to form hollow or recessed sections inside the casting.
• Made separately using core boxes.
Example: The hollow of a pipe or engine cylinder.
5.2 Core Print
• Extension on the pattern that supports and positions the core inside the mould
cavity.
Example: Cylindrical prints at both ends of pipe pattern.
6. Pattern Allowances (With Formula & Examples)
When molten metal solidifies, it shrinks, and machining requires extra material — thus
allowances are added.
Type Purpose Typical Value Example / Formula
Casting 100 mm in
Shrinkage Compensate for metal Al – 1.3%, CI –
steel → Pattern = 102
Allowance contraction 1%, Steel – 2%
mm
Machining Extra metal for Flange surface for
2–12 mm
Allowance finishing/machining machining
Taper for easy pattern
Draft Allowance 1°–3° Vertical faces
withdrawal
Type Purpose Typical Value Example / Formula
Rapping/Shake Accounts for sand loosening
Slight positive Manual moulding
Allowance before withdrawal
Distortion Depends on
To prevent warping L-shaped castings
Allowance shape
7. Pattern Colour Coding (BIS Standard)
Region of Pattern Colour Purpose
Surfaces to be machined Red Indicates metal removal after casting
Surfaces not to be machined Yellow Final surface
Core Prints Black Core support
Stop-off (no metal zones) Green Metal not to flow
Loose Pieces Orange / Stripe Easily detachable
Diagram Suggestion: Colour-coded 3D pattern illustrating each section.
8. Pattern Making Tools (Detailed)
(a) Measuring Tools
• Steel rule, vernier calipers, protractor, try square.
(b) Marking Tools
• Pencil, scriber, dividers, compass.
(c) Cutting Tools
• Hand saw, tenon saw, chisels.
(d) Forming Tools
• Files, rasps, planes (jack plane, smooth plane).
(e) Assembly Tools
• Hammer, nails, screws, adhesives.
(f) Finishing Tools
• Sandpaper, varnish brush, painting set.
9. Steps in Pattern Making Process
Step Description
1⃣ Study of Drawing Understand shape, size, and core positions.
2⃣ Material Selection Choose suitable material (wood, metal, etc.).
3️⃣ Incorporate Allowances Adjust size for shrinkage, machining, etc.
4️⃣ Cutting and Shaping Use tools to form basic shape.
5️⃣ Assembling Join different parts; add core prints, gates.
6️⃣ Finishing Smooth and paint using standard colour codes.
7️⃣ Inspection Check dimensions and accuracy before use.
10. Characteristics of a Good Pattern
• Accurate shape and dimensions.
• Smooth surface finish.
• Lightweight yet strong.
• Stable under humidity and temperature changes.
• Easy to remove and repair.
• Colour-coded for clarity.
• Economical in material and manufacturing.
11. Common Pattern Defects and Remedies
Defect Cause Remedy
Mismatch Misalignment of halves Proper dowels and parting line
Flash Poor sealing at parting Smooth, clean surfaces
Shrinkage cavity No shrinkage allowance Provide proper allowance
Distortion Uneven cooling or incorrect shape Use distortion allowance
Rough surface Poor finish or sand Finish pattern properly
Blow holes Improper core vents Ensure venting of cores
12. Safety in Pattern Shop
1. Wear goggles, gloves, and aprons.
2. Keep tools sharp and clean.
3. Avoid loose clothes near machinery.
4. Store wooden patterns in dry environment.
5. Ensure proper ventilation when painting or varnishing.
6. Maintain tool discipline — place tools back after use.
13. Real-World Industrial Applications
• Automobile Industry: Engine blocks, housings, gearboxes.
• Aerospace: Turbine blades, propeller parts (investment casting).
• Construction: Pipe fittings, valves, brackets.
• Machinery: Pump bodies, housings, pulleys.
14. Viva Questions & Answers
Q A
Replica of casting used to form mould
1. What is a pattern?
cavity.
To compensate for shrinkage, machining,
2. Why allowances are given?
etc.
3. What is the colour of core prints? Black.
4. What is a sweep pattern used for? Large circular shapes (pipes, tanks).
5. Which pattern is best for mass production? Match plate pattern.
6. What is the difference between pattern and
Pattern = model, Casting = final product.
casting?
7. Which material is best for one-time use? Wax / Polystyrene.
8. What is a skeleton pattern? Wooden frame pattern for large castings.
9. What causes mismatch defect? Misalignment of pattern halves.
10. What is the function of a core? To form hollow sections in castings.
15. Summary
• Pattern making is the foundation of the casting process.
• Proper design, material, and allowances ensure casting quality.
• Knowledge of colour coding, tools, and safety is vital for workshop practice.
• Precision in pattern making results in efficient, defect-free production.