A Gray and Ductile Iron Foundry
American Iron Foundry with No Bake Molding for Heavy Castings
Gray and Ductile Iron Foundry for General Industrial Castings
OK Foundry makes gray and ductile iron sand castings from 1 lb. to 400 lbs. With no-bake resin bonded sand molding for heavy section and complex cored castings up to 400 lbs. and manual jolt squeeze green sand molding for lighter castings.
For an iron foundry, a no-bake cope and drag molding is a flexible molding process that can be used with many configurations of legacy tooling. An iron foundry with a resin bonded sand process can make castings from almost any tooling in low volumes.
The no-bake molding line at OK Foundry is most efficient for short runs of 25, 50 or 100 castings of 50 to 250 lbs. in gray or ductile iron. Setups are quick on a no-bake molding line and frequent deliveries of short run castings can ramp production to significant volumes of lean supply. No-bake molding has the least expensive tooling of any sand molding process and is a good process for heavy equipment castings like pumps, volutes, gear cases and heavy boiler grates.
Phenolic Urethane No-Bake (PUNB) Binder for Difficult Iron Foundry Castings
To support the widest range of casting sizes, shapes, and configurations, OK Foundry utilizes phenolic urethane binders for cope and drag molding. Phenolic Urethane No-Bake binders (PUNB) create the strongest molds and cores.
Cores made with PUNB binders have superior hot strength and PUNB cores in cold boxes are easily reinforced with steel rods to prevent core bending and breakage.
Cope and drag resin bonded sand molding supports the widest range of tooling and most green sand patterns or foundry patterns from other processes can be run in resin bonded sand. No-Bake molding is appropriate for volume production of heavy section, complex cored and large format castings and castings with green sand patterns in small volumes.
Manual Jolt Squeeze Green Sand Molding for Smaller Iron Foundry Castings
Manual jolt squeeze green sand molding is the least expensive process for short runs of light castings, about 15 lbs. or less. Jolt squeeze molding is often used for older green sand castings with legacy green sand matchplate tooling and manual molding is easier to setup for lower volumes of castings.
Even modern patterns from automatic machines like the Hunter HMP-10 and HLM-10, can be molded on a jolt squeeze machine with a 14 x 19 flask for ramp-up or ramp-down production of light castings that have been tooled for automatic molding but have volumes that are too low for higher volume foundries.
Manual jolt squeeze molding is less expensive to setup and breakdown than automatic molding for economical production of lower volumes of castings or complex castings. When volumes increase, castings can be migrated back into automatic molding for the lowest cost per part.
3D CAD and CNC Milling Foundry Patterns
OK Foundry has full 3D CAD design and engineering capabilities with the latest version of Solidworks and full 3D CAD/CAM using FeatureCAM. See a short video below showing the in house CNC milling of large format foundry patterns on a CNC bridge mill and CNC milling core box.