For manufacturing processes, a casting method can be used to create a product by using a mold. The material to make the product, such as metal or plastic, is poured into the mold where it cools. The mold is then pulled away to reveal the part. The type of material that is used to make the mold will be based on the type of material that is used to create the component. Sand cast molding is often used to create parts and products by using various materials, as resin sand is commonly used by many manufacturers.
What is Resin Sand Casting?
Resin sand is a type of quartz sand that is mixed with a resin material. The chemical reaction created by the resin helps to bind and stiffen the quartz sand to make solid, hard and strong molds. The resin sand can be used to create just a part of the mold, or the entire mold material. The mold can create 3D products in a variety of shapes, configurations and sizes. Once the mold is made, materials are poured into the mold as the sand’s refractory properties help the mold remain stable. Then the sand is removed through a shakeout process as the metal is then cut, ground, finished and assembled into the final product.
While the mold itself is not reused since it is broken away from the finished component, the resin sand can be captured and reused to make other molds in the future. A wide variety of metals can be used in resin sand cast molding due to the sand’s tolerances to high temperatures. So iron, titanium and nickel alloys can be used in this process.
Resin sand casting provides amazing benefits for manufacturers who are looking to make complex parts in smaller production runs using cost-effective methods. One of the main benefits is that resin sand casting creates a very smooth mold surface that is strong and solid. The reason is because of the sand’s collapsibility when the mold compresses while solidifying. So there are fewer casting defects as the molten metal can flow into every crevice of the mold to create accurate dimensions.
Resin sand casting is ideal for very large castings that can weigh several tons. Yet this process is also ideal for smaller components that need customization. The process requires fewer workers to create the mold and production runs, which can also provide cost savings that can be passed on to the customer. Since the mold is very strong, it can make products for a wide range of applications, such as engine blocks, cylinder heads and other engine parts, hardware, electrical contact parts, pulleys, and even landing gear components.
Considerations When Using Resin Sand Cast Molding
One consideration when using this process is that it is not a fast method. The sand must be mixed and molded into the part, as the same mold cannot be reused repeatedly once the poured material solidifies in the mold. So this manufacturing method is typically ideal for intricate parts or parts of high-mix and low volumes. Otherwise, customers can take advantage of the capabilities of this process when using an experienced manufacturer. Here at Impro, we provide resin sand casting methods to provide high quality work for customers. We are especially experienced in complex engine blocks, cylinder heads, pistons, and machine frames. Contact Us today to learn more about our resin sand casting capabilities.