Casting the Future

In this process, the molding sand is chemically bonded. Hardening occurs through a liquid or gaseous catalyst. It is characterized by its flexibility and the ability to produce large components. In sand casting, a destructible lost mold is created, which offers great freedom in casting design. The process is also known by the following names: No-bake process, furan resin molding process, phenolic resin molding process, cold-box molding process, Pep-Set molding process.

Here we use a fully automated molding line with the Seiatsu process, also known as the air-stream squeeze molding process.

The mold production takes place via a two-stage molding material compaction process for bentonite-bonded molding material, involving pre-compaction in an air stream and final compaction by squeezing. This process is fully automatic and ensures a homogeneously compacted mold. The dimensions of our molding boxes are 1500 x 1050 mm. We recommend this process for components with suitable dimensions and higher production volumes.

In this casting process, a permanent steel mold is filled from above by gravity. Due to the rapid cooling rate of the aluminum in the steel mold, high mechanical properties are achieved in the casting. The surface quality also exceeds that of the sand casting process. In die casting, sand cores can also be used to create cavities.

Low-pressure casting is a further development of the gravity die casting process. Low-pressure die casting enables an automated and therefore controlled filling of the die from below. The rising, laminar flow of the liquid aluminum alloy leads to even higher casting quality and strength.

This process is ecologically unique because it uses neither chemicals nor water. The molding material is bonded solely by a vacuum and is 100% reused in a closed-loop system. The vacuum molding process is also unbeatable in terms of surface quality and accuracy.

For prototypes or single parts in the service sector, our 3D sand printing process is our customers’ preferred choice. The dimensions here are almost unlimited. 3D printing underscores the motto “time is money” and offers immense savings through its rapid implementation. The printing of cores for high-volume production is also realized.

In the so-called Job Box, silica sand is layered fully automatically with a thickness of 0.2 mm. The control system processes the 3D data we have created and prints the desired mold by selectively wetting the individual sand layers with resin and hardener. After these regions have cured, the desired mold is created.