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Quality Control
Our foundry strictly adheres to the ISO 9001 quality management system, and all products are certified to international standards such as CE and TUV.
Advanced Equipment
We are equipped with a comprehensive range of processing equipment, including CNC machining centers, lathes, drilling machines, grinders, fully automatic molding machines, advanced machining centers, surface treatment lines, assembly lines, and packaging lines.
Customization
We have a comprehensive foundry process and can provide customized production based on customer-provided technical drawings or samples. Through a variety of process methods, we can achieve different casting effects and standards (OEM or ODM) to meet our customers' individual needs.
Extensive Experience
With over 15 years of industry experience, all our processing technicians are professionally trained and have extensive practical experience, enabling them to complete various processing tasks efficiently and accurately. Our production team has an average length of service of over 6 years, and our annual production capacity reaches 100,000 tons.
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Production capacity |
Annual output of 5,000 tons, supporting large-scale customization |
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Service scope |
Integrated services covering research and development, production and sales |
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Material |
HT250/300, QT450-10, 304/316, duplex steel, etc |
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Process |
Sand casting, resin sand casting, precision investment casting |
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Customized services |
Support processing based on provided drawings or samples |
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Rapid prototyping |
Sample production is completed within 7 to 15 days |
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Customer guarantee |
12-month quality warranty |
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Global logistics |
Support international transportation |
Better Dimensional Accuracy: Shell mold casting products have excellent dimensional accuracy. This is because of a thin layer of cured shell, which maintains shape under heat and pressure. For medium-sized parts, you can achieve tolerances up to ±0.25 mm.
Good Surface Finish: Unlike sand casting, molten metal comes in contact with a dry closed shell, whose surface is smooth and non-porous. This results in less surface deformities and great surface, ideally up to 2.5 µm
Short Lead Times: Once the shell mold is made, you can re-use it with consistent results. This not only shortens the lead time but also makes the process economical for larger production runs of the same unit.
Reduced Level of Gas Defects: The process uses a higher binder content than other methods. Still, the thin-walled, hollow cores create natural ventilation paths. The improved permeability of coarser sand in the shell mold helps to eliminate gas buildup, resulting in better castings.
Automation Possibility: The shell casting process can be easily automated, which makes it suitable for high-volume manufacturing. There are machines that can handle all key tasks: metal pattern heating, shell formation, and assembly.
Versatile Material Support: Both ferrous and non-ferrous metals are castable via shell mold casting. This makes its use case versatile across materials.
Create All the Pattern Parts
The first step in shell molding is creating a pattern part. This is achieved by first machining a metal pattern tool, usually from iron or steel, in the shape of the part you want. Each pattern represents one-half of the part; a second pattern is required for the other half. If you're casting reactive metals, the pattern will need to be made of graphite rather than metal.
Construct the Mold
Molds can be repeatedly made from a single pattern. Lubricate the pattern with calcium stearate and then preheat it to between 175 ºC and 370 ºC. Next, place the pattern atop a “dump box” full of the sand and resin mixture. Flip the box so the resin and sand contact the pattern; the heat will cause the resin to cure.
Assemble All the Pattern Parts
After the shell has cooled, it can be ejected from the pattern tool and assembled with the other half of the shell in a flask. The flask is filled with a metal shot that fills in the space between the two-part shell and the flask's walls. Mold halves must be clamped tightly together.
Expose the Pattern to Molten Metal
Next, pour molten metal into the pattern. The metal can be poured in manually or using an automated machine.
Allow To Cool
After the molten metal is poured, it must be allowed to cool properly in room-temperature air. Any attempt to cool the casting actively and/or with liquid coolants can lead to changes in the metal's structure and properties. Total cooling time depends on the volume and specific type of metal involved.
Eject the Casting
Once the metal has cooled, it is ejected from the casting. This may be done by separating the mold halves at their seam or by simply breaking the mold itself. The mold material is easier to remove from the metal if it was properly lubricated before the molten metal was introduced.
Cast Iron
Cast iron was once the most cast metal due to its mechanical properties. Still, its use is prevalent in the industry. Fray cast iron, nodular iron, white cast iron, malleable iron, and alloy cast irons are popular for this casting.
Steels
Steel castings are known for their high tensile strength and toughness. The best steel options are:
● Carbon Steel: It is machinable and wear-resistant to fewer percentage alloying elements. However, it is more susceptible to corrosion compared to other types of steel.
● Alloy Steel: These steels contain additional alloying elements to enhance strength and hardness. Favorable grades for casting include 45Mn, and 40Cr.
● Stainless Steel: With high chromium content (about 10.5%), stainless steel is corrosion-resistant and durable. However, it can have a brittle nature plus its strength is not as good as carbon steel.
Aluminum Alloys
Aluminum alloys are suitable for lightweight applications for instance aerospace.
Copper Alloys
Copper is a ductile material with excellent conductivity and corrosion resistance. So, the use case is applications requiring these properties, for instance, electrical components. However, copper alloys are expensive and offer less strength than steel.
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Industry |
Applications |
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Automotive |
Engine blocks, cylinder heads, camshafts, crankshafts, transmission housings |
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Aerospace |
Turbine blades, gear housings |
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Industrial Machinery |
Gears, valves, pump housings, lever arms |
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Electrical Equipment |
Housings and components for electrical systems |
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Oil and Gas |
Valve bodies, Custom precision components |
Make a request
Make the drawings
Engineer's confirmation
Develop molds
Quality control
Laboratory testing
Sample confirmation
Mass production
Packaging
Shipment
Our Service
● If you need custom products, first we need open the grinding tool according to your technical drawing, then we produce the sample for your check.
● If it's OK for you, then we start mass production, and every product will go through staff-check, Inspection visits, and final detection, that's to say 100% check not spot-check.
● All products has a one-year warranty period.
● And we offer 24x7 service during pre sales, mid sales, and post sales.
Packaging depends on the mold, parts and customer requirements.
Proper packaging and professional couriers will ensure fast and good delivery of goods.
We're professional shell mold casting manufacturers and suppliers in China, specialized in providing high quality customized service. Be free to wholesale discount shell mold casting for sale here and get quotation from our factory. For price consultation, contact us.
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