Metal casting offers OEM designers tremendous flexibility in design, material properties and cost. Tooling options range from rapid prototypes good for a few parts to intricate patterns capable of hundreds of thousands of molds. Depending on application, quantity and design/function requirements, The Estell Group can help you evaluate your most cost-effective options.
Sand molding is the most common type of casting process, used for nearly all industrial and automotive alloys (aluminum, iron, steel, bronze, brass, etc.). Good for very low to high volume, depending on tooling construction. Sand castings will have the highest range of dimensional tolerance, and typically require machining.
TEG foundries offer the following sand-casting options:
Automated green sand molding, best suited for medium to high volume jobs with relatively frequent and repetitive demand:
Airset molding, used frequently for prototype parts, large castings, lower volumes or parts with complicated core configurations. Flexible flask sizes, determined by the parameters of each part:
Cope & drag and jolt squeeze molding offer a variety of flask sizes - dependent on part design - in a variety of alloys. Older and/or lower volume jobs with existing tooling often utilize these processes:
Permanent Mold Gravity Chill casting is a very cost effective way to obtain challenging net shapes with reduced machining machining requirements. Parts can be molded from multiple axes, offering significantly greater design flexibility than standard two-axis sand casting. Coring and slides can be used to form a variety of complex features, reducing or eliminating machining, particularly considering the consistency and relatively tight tolerances held in the permanent mold casting process. Assembly costs and tolerance stack can frequently be reduced by combining multiple components in a single permanent mold casting design.
Automation increases permanent mold throughput and process control, and parts are often processed with minimum human intervention until cleaning or machining operations. Best suited for medium to high volume production, TEG partner Bertazzi & Soldi offers as-cast and machined permanent mold gravity castings in:
Die casting uses pressure to force aluminum or zinc alloys into high-precision molds. While tooling is relatively expensive, piece pricing is typically low and machining costs are minimal compared to most other casting processes. Slides are used to form precise bolt patterns or blind holes, reducing machining requirements. Excellent as-cast surface finish. Stroh Die Casting offers die castings produced with up to 900 ton presses yielding up to 15 lb castings in:
Investment casting, also know as the lost-wax process, offers the most complex shapes, with a very high degree of precision. difficult machining and/or assembly operations can be eliminated by design. A variety of materials can be cast in this process, with TEG partner Milwaukee Precision Casting offering: