Process

1. Discovery – We conduct a discovery call with a potential customer to get all details needed to provide an accurate quote. We’ll research options with scaling and delivery to ensure we offer the most competitive pricing available to you. 
   1. Patterns – We perform basic pattern modifications and maintenance in house. If major changes or new tooling is needed, we work with dedicated local pattern makers to ensure that you will receive high quality, durable tools.
   2. Cores – We produce many cores in house, including airset, oil sand, and shell cores. Just as with patterns, we routinely perform basic core box modifications and maintenance in house. If core boxes need major changes, replacement, or brand new tooling, we can work with our local pattern makers to get you the right solution. We frequently produce cores for other local foundries. Please inquire if you are in need of cores. 
2. Molding – 
   1. Green sand molding equipment consists of two squeezers, a roto-lift machine, and a heavy floor molding area. Mold sizes in green sand start at 10 by 12 4/4 and progress up to 36” by 39” 12/24. Green sand molds are poured daily and the sand is then reclaimed for future use.
   2. Airset molding is accomplished with a Palmer continuous mixer. Mold sizes are limited only by our 500-pound maximum pour weight. Custom flasks can be constructed to accommodate a huge variety of tooling. Molding with loose patterns is also routinely performed. Airset molds are noted for their high-quality surface finish.
3. Melting – We utilize Inductotherm coreless induction melting furnaces with 100, 300, and 500-pound melt capacities. This allows us to manufacture parts with pour weights as low as a few ounces and up to 500-pounds.
4. Finishing / Grinding – Casting finishing begins in the molding department where our skilled personnel strive to make it easy on the grinders by producing high quality castings. Castings are blast-cleaned in either our table blast or tumble blast machine. Grinding is accomplished via Fox stand grinders, along with numerous hand held pneumatic grinders. Parts requiring heat treatment are sent out to local facilities as needed. Some castings are machined in-house or sent out to one of the area machine shops we routinely work with.
5. Quality Assurance – We assure quality throughout every step of the process by utilizing thermal analysis in the melting process along with on-site optical emission spectrometry to control our melt composition. We also perform Brinell Hardness verifications and work with a third party lab to perform mechanical analysis. Our quality system has been ISO 9001 2008 registered.
6. Paint & Priming – Many of our customers do not require this step in the process but we have the capabilities to perform these tasks if desired.
7. Shipping & Delivery – Each casting is inspected for fit and function prior to shipment. Depending on our customers’ location, we may deliver the parts personally. We are committed to ensuring that our customers are satisfied with our work.