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CPM Industries

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Technical Stuff Casting Technologies
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CPM Industries uses a combination of the following Casting Technologies.

Green Sand Casting-

The Green Sand Casting Process is by far the most diversified molding method used in present casting practices. The process utilizes a mold made of compressed or compacted sand. The mold material consists of a silica based sand mixed with a suitable bonding agent (clay) and moisture. If the casting has hollow sections or undercuts, a core consisting of hardened sand is used to form the hollow section. Some of the advantages of green sand casting are that most alloys can be cast and the pattern costs are relatively low. This method is adaptable to large or small quantities and can be produced rather quickly.  CPM Industries uses green sand for Prototype Casting projects as well as Production Casting projects, usually smaller castings with less detail and typically under 14''x14''.  We use this technology for Aluminum Prototype / Production, Cast Iron Prototype / Production, and Magnesium Prototype / Production casting projects.

No-Bake or Air-Set  Casting-

The Air-Set molding process utilizes a mold made of silica based sand mixed with furan and urethane binders. The binders allow the molder to control the setting time by the addition of specific amounts of catalyst. This feature, combined with high strength and desirable range of heat properties, works with various alloys and presents the opportunity for great flexibility in mold making. One advantage to this method is better dimensional control and accuracy. Just like green sand casting, hollow sections and undercuts can be created with the use of cores.  CPM Industries uses Air-Set sand for Prototype Casting projects with high complexity.  We also use Air-Set for Production projects requiring a high level of detail such as heat-sinks.  We use this technology for Aluminum Prototypes / Production, Ductile Iron Prototypes / Production, Cast Iron Prototypes / Production, and Prototype Magnesium casting projects.

Plaster Molding (Simulated Die Casting):

Plaster molding utilizes a mold made from plaster instead of sand. This process is done by pouring liquid plaster over the pattern, then the mold must be dried in ovens for typically 24 hours before metal can be introduced. Plaster molds are strong, relatively precise molds that enable the casting to yield better casting tolerances and thinner wall sections. The use of plaster or sand cores can be used to create hollow sections and undercuts. Plaster molding can be relatively expensive as compared to sand casting but with certain designs this may a necessary method.  We use this process only for Aluminum Prototype Castings and Production Aluminum Castings.

Rapid Core Technology (Tool-Less):

Rapid Core Technology is when sand molds and cores are printed using a machine similar to an SLA machine.  This process is only used on the most complex shapes and most of the time is used in very low quantity projects.  Since no tooling is created, the initial investment on overall project cost can be reduced.  In some cases the delivery of parts can be drastically reduced as well. CPM Industries uses this technology for use with Prototype Aluminum, Prototype Ductile Iron, Prototype Cast Iron and Prototype Magnesium casting projects.

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Casting Technologies