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.