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 green sand molding for lighter castings. No-bake cope and drag molding is a flexible jacket less molding process and can be used with many configurations of legacy tooling. No bake resin bonded sand is also very flexible for making smaller volumes of cores from legacy high volume tooling.
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.
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 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.
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.