Permanent Mold Casting

Permanent mold casting is the process of introducing molten aluminum into reusable cavities to produce superior castings. Our in-house permanent mold casting facility offers various gravity pressure casting processes to provide high-quality aluminum and zinc castings that suit every customer’s needs. Engineers provide casting design assistance, solid modeling, gating and flow analysis, plus prototyping and modeling to ensure each project is perfectly crafted to customer specifications.

Advantages

• Intricate design capabilities with high dimensional precision
• Castings with excellent mechanical properties
• Excellent surface finish with consistent quality
• Cost-effective castings due to design, tooling life and production processing
• Rapid low-cost prototyping with graphite permanent molding

 

Design and Mold Production 

With in-house mold making capabilities, our expert design team can work with you to make your concept into reality. Our experienced staff can design, engineer and manufacture tooling from scratch with the use of state-of-the-art CAD and CAM software. Conveniently, we can also alter, modify, and/or repair existing tooling.

Casting Capabilities

Our modern static and tilt-pour permanent mold facility has ten furnaces for a total capacity of 10,000 pounds, producing aluminum or zinc parts ranging from 1 ounce to 150 pounds. With a variety and various sized casting machines, our foundry allows us to operate efficiently and to deliver a wide range of high-quality castings to our customers on time.

Permanent Mold Production

• Tilt Pour Permanent Mold – Molten metal is poured into cups while the mold is in a horizontal position and flows into the cavity as the mold is gradually tilted into a vertical position. As the molten metal flows into the mold cavity at a controlled, gradual rate, there is little turbulence present, resulting in a high-quality casting.
• Static Pour Permanent Mold – Molten metal is poured directly into the mold and fed by gravity. A fixed amount of time is given for the metal to solidify in a stationary position.
• Semi-Permanent Mold – Introducing sand cores to either tilt or static permanent methods. Temporary sand cores create a non-machined shape or passageway within the casting for a variety of customer requirements.

 

Graphite Permanent Mold Production

Excellent for smaller sized parts using a bottom fill, low turbulence process, that produces high quality, homogenous castings with an outstanding surface finish. Graphite molds are an economical option for any quantity of zinc castings or an excellent alternative for lower volumes or prototypes of aluminum castings.

Core Production

The use of a bonded sand to produce inserts for desired shapes, passageways or relieve drafts in the casting process without machining.

Finishing Processes

• Cutting – The process of trimming gating, excess material from a casting
• Grinding – Utilizing abrasives to remove parting lines and other excess material from a casting
• De-burring – The process of filing down unwanted edges or lines from a casting
• Shot Blasting – A process typically utilizing steel media to blast the surface of a casting, effectively cleaning and texturizing the metal
• Vibratory Finishing – Tumbling process to deburr, descale, burnish or clean and polish castings
• Heat Treatment – The process of improving the mechanical and physical properties of an aluminum casting
• Impregnation – Effectively seals against leaks and other damaging agents