Customer supplied designs are promptly put into the production schedule where CAD operators slice the part into workable pieces for the CNC machines.
Ten state-of-the-art CNC machines precision cut each layer of the design from Styrofoam blocks.
Styrofoam layers are assembled by hand, creating each one-of-a-kind pattern.
Each pattern is visually and dimensionally inspected before it is sent to the casting center.
Refractory wash is applied to each pattern and serves as the protective layer between the molten metal and the molding sand.
The pattern is hand packed with a sand and binder mixture that is controlled by one of five no-bake sand mixers.
Rotation of flask
Once the Full Mold is cured, it is rolled over and the bottom plate is removed.
The gating system is designed to allow the molten iron to fill the mold at a controlled rate.
Metal chemistry is verified after scrap steel is melted by one of three 15 ton electric furnaces.
Metal tapping into the ladle
Once the alloy content and desired temperature are reached, molten iron is tapped into a ladle.
Ladles lined with brick keep the metal at a constant temperature while cranes transport the ladles to the molds.
The molten iron flows thru the gating system and into the mold, evaporating the pattern as it fills.
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.
Shotblasting cleans any remaining sand and coating from the casting.
Finishing - gate removal
Gating material and handling risers are removed.
Castings are inspected and ready for shipping.