Z Corp Process

Flowserve Dayton Foundry utilizes the Z Corp rapid prototype process. This process produces cast metal parts from a 3D CAD file faster and less expensively than many other available rapid prototype casting methods.

Through the Z Corp process, patterns are printed on a 3D printer directly from digital data. The foundry then uses the investment casting or lost wax method to produce molds, dipping them in wax and then ceramic slurry. With the Z Corp process, customers can take full advantage of the complete range of metal alloys produced at the foundry to have castings manufactured.

The Dayton Foundry’s rapid prototype process eliminates the requirement for the customary wood, plastic, metal pattern and core box used in the conventional sand molding process. The foundry also has the capability to produce 3-D models.

Z Corp Capabilities


Flowserve pours stainless steel, nickel-based and cobalt-based alloys in accordance with several specifications, including ASTM. Custom alloys also can be produced.

Maximum Weights

150 lb (91 kg) gross; 100 lb (68 kg) net

Minimum Casting Wall Thickness

3/32 in (2.381 mm) nominal; 1/16 in (1.587 mm) depending on part configuration


±0.020 in/in (±0.020 mm/mm)

Surface Finish

150-250 RMS (as cast)

Quality, Inspection, Testing

A full range of laboratory, mechanical and non-destructive testing services is available as required.

Routine procedures include:

  • X-ray fluorescence spectroscopy
  • Leco carbon and gas (H, N, O) analysis
  • Mechanical testing (tensile and impact)

Note: Due to the customized method of the Z Corp process, some variations in wall thickness, tolerances and surface finishes are possible.