Author Archive Skellerns

Auckland Foundry (Head Office)

November 16, 2023 Comments Off on Auckland Foundry (Head Office) By Skellerns

Skellerns Metal Casting expanded its metal casting offerings and facilities when moving from Honan Place, Avondale to our current and head office location at 86 Patiki Road, Avondale when it acquired the assets of Progressive Castings Ltd in 2016 which was renown for its metal sculpture castings, furniture and design cast products as well as its commercial and racing performance castings.

The multi building foundry provides well equiped designated areas for its variety of metal casting teams, from Bronze plaques, larger than life Artwork & Sculptures, to industrial and commercial cast metal products.

From its high temperature electrical induction furnaces for metal melting combined with pouring solutions for hardsand and greensand casting and investment Loss wax metal casting process through to its weilding and shot blasting area and machinery for our teams to to complete and finish of a cast metal product.

Auckland Foundry (Head Office) Location

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Hamilton Foundry

November 16, 2023 Comments Off on Hamilton Foundry By Skellerns

Skellerns Hamilton foundry operating since 1976, located at 35 Ellis Ave Frankton, predominantly offers a wide range of metal casting services and products to municipal councils, construction and utilities providers with our drainage and streetware products and concretework and fabrication.

In 2014 Skellerns acquired Surecast Metals Ltd which was owned and operated by manager Ken Chisholm this acquisition has allowed Skellerns to expand its existing range streetware: grates, manhole covers, toby boxes and concrete fabrication and components with the support of our other foundries to include bronze and other metal plaques castings, bronze artwork and sculptures, and other industrial metal castings as well the addition of marine industry metal castings.

Hamilton Foundry Location

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Palmerston North Foundry

November 16, 2023 Comments Off on Palmerston North Foundry By Skellerns

As of 15 November 2023 Skellerns acquired the assets of Cast Components Ltd a purpose built foundry at 99 Keith Street, Roslyn, Palmerston North established by Murray Hamlin in 2004.

Our new Palmerston North foundry retains its New Zealand owned status and has enabled Skellerns to add to its metal casting offerings to include a wider variety of industrial, quarrying, mining and general engineering products and services previously provided by Cast Components and expand on its existing product range.

Over the years Investment has continually been made in the plant and equipment to offer five tonne gantry cranes allowing for us to tackle a variety of different sized projects.

Past projects of Cast Components from the Palmerston North Foundry

The structure for the Lampton Quay Bollards, A memorial sculpture honouring Sapper Horace Moore-Jones, a kiwi wartime Artist who’s water colour sketches provided a real insight to the Gallipolli Campaign and the Solace Statue on Wellington Waterfront designed by artist Max Patte who worked for the Weta Workshop.


Palmerston North Foundry Location

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ARTIST GALLERY

July 24, 2023 Comments Off on ARTIST GALLERY By Skellerns
Bronze Sculpture “Moment of Release” by Sue Dinkelacker & Dell Pryor

Click on the Thumbnail image to visit the Artists website.

SAND MOULDINGS & INVESTMENT CASTINGS

September 1, 2020 Comments Off on SAND MOULDINGS & INVESTMENT CASTINGS By Skellerns

Skellerns Metal Casting is one of New Zealands top foundries for Green Sand Moulding, Hard Sand Moulding and Investment (Lost Wax) Castings using the lost wax process for detailed precision work.

Investment casting or Lost wax casting

As one of New Zealand last remaining investment casting operations we offer the full range from one off castings to high volume scale lost wax castings. From one off 3-D printed patterns to high volume parts through lost wax moulding we cover the range in 30 different casting metals either in non-ferrous or  ferrous metals.

3D design and printing service

Skellerns Metal Castings also offer an inhouse 3D design and printing service for low volume economic investment cast patterns or high volume aluminium lost wax moulds. Our staff have more than 30 years’ experience in the investment casting process so there isn’t much we haven’t cast over this time.

Sand Moulding

At Skellerns Metal Casting Ltd we use 3 different types of sand-casting methods ensuring we match the most economically way to produce metal castings to your requirements.

Our casting methods in sand cover:

  • High Volume Shell Moulding
  • Medium Volume Green Sand
  • Low volume resin Hard Sand

Sand casting can produce metal to any size or shape eliminating the need for expensive engineering fabrication and wasted metal. Better still it is good for the environment as much of the metal is recycled metal.

Skellerns offers pattern services to help produce your patterns, we also have our own 3-D printer for those that want a low volume production pattern at low cost. Our casting range is from 20 grams to 500Kgs. We cast both ferrous and non- ferrous metals.

Sand casting is a versatile and creative technique that can be used for various purposes, from art, engineering and industrial parts. If you are interested in learning more about sand casting.

This scope of expertise enables us to be more versatile and flexible when selecting the most appropriate methodology to achieve your desired metal casting outcomes.  

At Skellerns we take great pride in our attention to detail and providing high quality metal castings and customer service.  

Working with Patterns

Castings from Existing Patterns

For bronze, aluminium and other metal castings, when you provide us with your existing patterns the Skellerns team will use their metal casting expertise and skills to ensure the highest quality and economical resulting products. 

Design & Process Guidance for New Patterns

Our experienced Sales & Support team will collaborate with you to ensure they understand all your requirements completely. With their wealth of industry knowledge they provide you technical guidance throughout the entire pattern design process and ensure it is prepared and ready to meet your timeframes.

Metal Casting Processes

Green Sand castings process is performed by using sand moulds formed from “wet” sand which contains water and organic bonding compounds, typically referred to as clay.  The “Green” of Green Sand Moulding is not in reference to the colour of sand but relates the sands state.  The name relates to the fact that the sand mould is not “set”, it is still in the “green” or uncured state even when the metal is poured in the mould.

Advantages of Green Sand Moulding:

  • This is the least expensive process when producing small quantities (normally less than 100) and also boasts with the least expensive tooling.
  • Range of casting sizes – ability to cast very large parts.
  • Flexibility in metal choice – Both ferrous and non-ferrous metals can be casted using this process.
  • Economical – A low production cost due to materials used and little post-casting tooling required.

Disadvantages of Green Sand Moulding:

  • Lower degree of accuracy – dimensional accuracy is less than that delivered by other processes.
  • Tolerances limitations – This process requires large tolerances. Surface roughness – The surface finish for ferrous casts delivered usually requires additional work.
  • Weight excess – Castings produced with this proceed usually exceeds the calculated weight.

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

Investment Casting is a more accurate method for creating more precision for intricate castings. It would be used for small engineerings works, artwork and items that have under cuts.

  • Slightly more expensive – This method utilises high quality wax which is more expensive than Hardsand or Greensand.
  • Higher quality output – The use of wax creates greater precision in the metal casting end product.
  • Less additional work – the resulting metal cast product is more precise therefore less finishing is required

Metal Casting Finishes

At Skellerns Metal casting we offer a range of metal finishes which includes:

  • Metal Polishing
  • Sand and shot blasting
  • Heat treatment
  • Fettling
  • Patina

Examples of metal cast product finishes.