CAD programming
Customer supplied designs are promptly put into the production schedule where CAD operators slice the part into workable pieces for the CNC machines.
step 1/16
CNC cutting
Ten state-of-the-art CNC machines precision cut each layer of the design from Styrofoam blocks.
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Pattern assembly
Styrofoam layers are assembled by hand, creating each one-of-a-kind pattern.
3/16
Quality check
Each pattern is visually and dimensionally inspected before it is sent to the casting center.
4/16
Coating
Refractory wash is applied to each pattern and serves as the protective layer between the molten metal and the molding sand.
5/16
Molding
The pattern is hand packed with a sand and binder mixture that is controlled by one of five no-bake sand mixers.
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Rotation of flask
Once the Full Mold is cured, it is rolled over and the bottom plate is removed.
7/16
Gating system
The gating system is designed to allow the molten iron to fill the mold at a controlled rate.
8/16
Melting
Metal chemistry is verified after scrap steel is melted by one of three 15 ton electric furnaces.
9/16
Metal tapping into the ladle
Once the alloy content and desired temperature are reached, molten iron is tapped into a ladle.
10/16
Metal transport
Ladles lined with brick keep the metal at a constant temperature while cranes transport the ladles to the molds.
11/16
Pouring
The molten iron flows thru the gating system and into the mold, evaporating the pattern as it fills.
12/16
Casting removal after cooling
Castings are removed after the required hold time, the empty mold is shook out and 97% of the sand is reclaimed.
13/16
Shotblasting
Shotblasting cleans any remaining sand and coating from the casting.
14/16
Finishing - gate removal
Gating material and handling risers are removed.
15/16
Shipping
Castings are inspected and ready for shipping.
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