Moulding Techniques

Proposal of the optimum manufacturing techniques require a range of casting processes:

Self-Set Floor

The solid sand structure of air-set sand moulds allows small to large intricate castings to be moulded. This method also keeps sand use to a minimum and the majority of it can be reclaimed without compromising quality, thus creating further savings for the customers.

Block Carousel

To increase productivity, we have the facilities to batch produce multiple or single pattern ‘boxless’ pattern jobs. Two mould handling carousels satisfy demands for economy due to their high moulding productivity and sizes of patterns which can reach up to 2000mm in length and 1000mm in width.

High Definition ‘Petrobond’

High definition sand mouldings are traditionally hand-moulded using ‘Petrobond’, clay-bonded natural sand to give an exceptional surface finish when required. This technique is mainly used when producing castings of near-net-shape, vacuum former moulds and low cost mould tools. Even the detail of a fingerprint would be visible when cast, so this method requires traditional skill in production and is mainly used for limited-run or one-off casting.

Green Sand Floor Mould

The hand rammed ‘greensand’ moulding process was the most widely used method of moulding and is not largely superseded by self-set sand systems. At FSE we can still use these techniques if required due to the experience of moulders available. The main reason for the choice of this process would be to utilise existing patterns which do not justify new pattern investment.

The green sand moulding process is usually used for smaller castings in both Aluminium and Copper based metals. Fine sand and clay are used, giving versatility and producing castings with excellent surface finish. 95% of the sand can be reclaimed, thus allowing a relatively low cost production technique.

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