Process
At Bhuwalka Castings we follow two manufacturing processes, one is the Conventional molding system by using Wooden, Aluminium & Thermcole Patterns, this process is suitable for customers looking at high volume of the same parts and are required regularly.
The other process is the Full Mould Process (Lost foam process) in this process thermcole pattern will be used & will be consumed during the process, this process is suitable for customers who do not have repeated requirement of the same part and is based on project requirement & Parts with higher complexity.
What is Full Mould Process
Full-mold casting is an evaporative-pattern casting process, It uses an expanded polystyrene foam pattern, which is then surrounded by sand, much like sand casting. The metal is then poured directly into the mold, which vaporizes the foam upon contact.
Pattern is consumed during the process.
Advantages of Full-Mold Process
- Supports complex shapes
- Highly accurate
- Highly efficient (produces little or no waste)
- Costs less than traditional wax-based casting processes
- Doesn’t require draft or flash
- Supports a variety of sizes, ranging up to several tons.
- Can be used with molten aluminum, steel, iron, copper, alloys and
many other metals.
Disadvantages of Full-Mold Process
- While relatively inexpensive when performed for high-volume applications, such as the mass-production of goods, full-mold casting typically costs more than other casting processes for low-volume applications.
- Every time new Pattern required for every new costing.
What is Sand Casting Process
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. Molds made of sand mixed with resin, to develop the strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in mold boxes. The mold cavities and gate system are created by compacting the sand around models called patterns, by carving directly into the sand,
Advantages of Sand Casting
- Suitable for mass production
- Versatile – Size, Weight, Shape
- Faster – Since there is no need to manufacture tooling for every casting
- One Time Tooling Cost
Disadvantages of Sand Casting
- Variation in Dimensional Accuracy & Casting weight.
- Pattern Maintenance.
Conventional Molding Process
Conventional Molding, is a metal casting process characterized by using sand as the mold material. Molds made of sand mixed with resin, to develop the strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in mold boxes. The mold cavities and gate system are created by compacting the sand around Wooden/Aluminium patterns, by carving directly into the sand. Same Pattern will be used for repetitive Molds.
