At the heart of groundbreaking engine development lies the precision of investment casting. And the foundation of every great casting? A perfect wax pattern.
24 Apr 2025
While high-volume production relies on tried-and-tested injection moulding, the journey to get there – the crucial phase of prototyping, refining, and optimising – demands flexibility and speed.
Overcoming Industry Challenges
Traditionally, creating unique wax patterns for each design iteration quickly can be a bottleneck. We've utilised wax 3D printing technologies in the past, but many standard machines present a significant hurdle: incomplete burnout.
Imagine painstakingly designing and printing a complex wax pattern, only for it to leave behind stubborn ash residue within the investment mould during the burnout process. This contamination ruins the final casting, compromising surface finish and potentially the integrity of the part itself. It’s a frustrating setback!
Flawless Wax Patterns, On Demand
We knew there had to be a better way. After rigorous exploration, we identified and have now successfully implemented a process using advanced materials that burn out cleanly from the investment mould, leaving no trace behind. This breakthrough paves the way for castings with brilliant, perfect surface finishes – crucial for high-performance engine components.
And, we've taken it a step further, with the installation of our new, state-of-the-art Wax 3D Printing machine right here at PC1.
This isn't just another piece of equipment; it's a strategic capability that fundamentally changes our prototyping workflow. Why?
This advanced 3D printing capability is the perfect bridge during the critical design and optimisation phase. It allows us to iterate, test, and perfect components with speed and confidence.
Once a design is finalised and validated ("locked down"), we then transition to the established methods for mass production – commissioning the injection moulding tools required to produce these components in volume efficiently.
Are you interested in the HX50? Book your spot in our group presentation and learn why the HX50 will be better than your current helicopter.
What's in the presentation
Who
Mischa Gelb (aka Pilot Yellow) and Ruben Dias
What
Exclusive full details about the HX50 not yet available to the public
How
30 minutes presentation + Q&A
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HX50
Exterior Concept
Interior Concept
GT50 Turbine Engine
General Aviation 2.0
Hill Digital Cockpit
Journey to HX50
Technical Details
Range Simulator
ADDRESS
Hill Helicopters
Unit 3, Shackleton Way
Stafford, ST16 1GY
United Kingdom
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