Originally developed for sheet metal forming tools in the automotive industry, kirksite material is a zinc/aluminum alloy (94 percent Zn, 6 percent Al) with a melting point of °F. Due to the vapor pressure of the zinc, the material is almost immune to the gas porosity encountered with other alloy systems and the. Cast aluminum and zinc kirksite tooling offer a simple and low-cost method of tooling. Disadvantages include a distortion of tools, accuracy. Why is Experi-Metal able to offer high quality prototypes at low volumes? Kirksite tooling is just one process that we utilize to meet the needs of our valued.


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Given cast kirksite tooling casting temperature of both aluminum and zinc it is important to replicate the initial pattern into a material capable of withstanding such heat. We use this process to develop prototypes for clients in a wide variety of industries.

Cast Kirksite Tooling

To learn more about our capabilities, click here. The molds cast kirksite tooling cleaned up and machined to fit into a standard mold base with ejection and runner systems or they can be used on a stand-alone basis.

The molds are then mounted into a traditional injection press of the appropriate tonnage and parts are run. Any required heating or cooling systems can either cast kirksite tooling cast in place or added later by drilling.

The molds are kept as simple as possible and built for speed, not necessarily efficiency.

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  • Mold Base (Kirksite) Alloys

Hand-loaded loose pieces are used instead of mechanical pullbacks and slides. Four or five hand loads are not uncommon, although this slows cycle time and increases unit cost. The Design Considerations Most of the design considerations used in creating injection molded parts cast kirksite tooling the same in prototype part design-including draft, fillets, radii and wall thickness.

Parts run in cast kirksite molds cast kirksite tooling range in size from a one-inch cube envelope to an approximate twenty-four-inch cube.

Raw parts from cast kirksite mold set. Press dies and punches for sheet metal forming.

Cast Kirksite Re-Emerges as RT Approach for Molding Plastics

Molds for ceramics and rubber. Injection molding and compression molding dies.


Parts can be moulded in two to three weeks in any thermoplastic cast kirksite tooling resin, This technology has been around for many years, but with the growth of stereolithography and the need for rapid turnaround of plastic parts in the correct production material, the kirksite approach has re-emerged.

More complex parts can be made using handloads.

Moulding tapers are important and are best incorporated in the master file.