Processes

Processes

Hard Sand Moulding

Hard Sand moulding  is characterised by using sand as the mould material.  In addition to sand often a bonding agent such as resin is coupled with a hardener and mixed with the sand. This allows the sand grains to essentially be glued into place as they are moulded around a pattern of the shape that you want.  The resultant hardened sand mould is what the molten metal is then poured into.

Hard Sand Moulding Advantages

The Hard Sand moulding process can have specific advantages over other manufacturing processes, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. Some of the benefits are in the processes flexibility:

  • Variety of metals able to be cast – ability to use both ferrous or non-ferrous metals.
  • Automated or hand crafted for accuracy – Mould replicates the component with high level of accuracy and consistency.
  • Jobbing or low volume production – ability to produce from 1 to 1000 units per run.
  • Complex shapes – undercuts and hollow centres can be formed and the process is capable of producing very large pieces.
  • Minimal wastage – Scrap and moulds can be and are often recycled

Other Casting processes utilised Green Sand MouldingShell MouldingDie Casting
Our metal casting experts will happily discuss which process best serves your casting requirements, simply call or contact us.

Shell Moulding

Shell Moulding is an expendable mould casting process that uses a resin covered sand form the mould.  The shell mould is a thin-walled shell created from applying a sand-resin mixture around a metal pattern of the desired casting.  The most commonly use metals for shell moulding are cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys.

Shell Moulding Advantages

The shell moulding process can have significant advantages over other manufacturing processes, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. Some of the benefits are:

  • Variety of metals casted – ability to use both ferrous and non-ferrous metals
  • Automated for accuracy – Mould replication of component with high level of accuracy.
  • Mass production – ability to produce from 100 to 10000 units per run
  • Complex shapes – fine details can be formed with very good surface finish.
  • Minimal wastage – Scrap and moulds can be recycled

Shell Moulding Disadvantages

  • Higher production costs and casting prices – Materials used are more expensive.
  • Higher pattern costs – process uses metal patterns which is more costly to create.
  • Large quantities required to become cost effective.
  • Size and weight limitation – The moulding machines may have sizing restriction.

Other Casting processes utilised Hard Sand Moulding; Die Casting, Green Sand Moulding

Our metal casting experts will happily discuss which process best serves your casting requirements, simply call or contact us.

Die Casting

Die casting is a manufacturing process in which molten metal is poured or forced into moulds. The moulds also known as tools or dies, are specifically designed to produce each component to be created and duplicated with a reasonable degree of precision. The most commonly used die casting alloys at Skellerns are gravity die cast aluminium and brass.

Die Casting Advantages

Die casting can have specific advantages over other manufacturing processes for high volume production, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. Some of the benefits are:

  • Better surface finish and dimensional capability – tighter tolerances
  • Fast and efficient production – ability to reproduce multiple of the same component and product.
  • Improved mechanical properties compared to sand casting.
  • Reduction in material scrap – with fewer steps from raw material to finished part

Other Casting processes utilised Hard Sand MouldingShell MouldingGreen Sand Moulding

Our metal casting experts will happily discuss which process best serves your casting requirements, simply call or contact us.