We are equipped with advanced shell molding production lines and complete supporting facilities, offering one-stop solutions from resin-coated sand preparation, heated pattern molding, shell curing to metal pouring and subsequent machining. Compared with traditional casting methods, shell molding provides higher dimensional accuracy, excellent surface finish, and better consistency in complex geometries. It is especially suitable for medium to large-scale production, thanks to its high efficiency, low material waste, and cost-effectiveness. With strict process control and professional heat treatment capabilities, we ensure each shell molded casting achieves superior mechanical properties, smooth surface quality, and excellent repeatability, making it ideal for automotive, machinery, and industrial equipment applications.
Step-by-step overview of the Shell Molding Casting method
A two-piece metal pattern is created in the shape of the desired part with a pouring cup to introduce molten metal into the ‘shell’. To create a two-part shell, in which two halves are combined to create a full shell, two metal patterns must be produced.
Set temperature, pressure and curing time for the metal pattern. When the pattern is heated to the appropriate temperature, the precoated sand is shot into the cavity. The shell half is then ejected from the metal pattern when it is cool.
The two halves are sealed using glue, or a combination of glue and other fasteners to form a shell which is similar to the ceramic shell used in the investment casting process.
The completed shell is baked at the oven at setting time and temperature. The subsequent process is the same as the investment casting technology-----
The shell is then placed into a flask and send to the vibrating table. The shell is firmly supported by sand and is ready to get poured.
The metal (steel scrap) is melting in the induction electric furnace and certain alloy is added to each furnace if necessary. Metal is heated to 1530-1580℃ in molten state and is poured into the shell while it is still hot – liquid metal flows into the pouring cup, through the central gating system, and into each mold cavity on the tree. The pre-heated mold allows the metal to flow easily through thin, detailed sections.
Once the metal is sufficiently cooled and solidified inside the shell, it's time for shakeout. Shakeout is basically vibrating the shell and casting so that the shell breaks apart and fall way. After removal, the castings are sent to sand blasting to remove the extra sand on their surface. After that the casting are separated from their gating system tree by using different methods such as manual impact, sawing, cutting, etc.
Finishing operations such as grinding, soldering, sand blasting, machining and straightening are commonly employed to smooth the part at the gates and remove imperfections such as sand holes, slag eyes, flash burrs, bulging, deformation and so on. After passing visual inspection, depending on the part that being cast, heat treating is to be employed to harden the final part.
High-performance materials optimized for shell molding casting applications
Alloy steel castings produced by shell molding offer superior strength and toughness, making them suitable for complex parts with strict performance requirements. The process ensures excellent repeatability and surface quality.
Carbon steel is one of the most commonly used materials in shell molding casting, offering a balance of strength, durability, and cost-effectiveness. It is ideal for structural and mechanical parts that require both precision and strength.
Relying on powerful and matchless machining finish capabilities, our company expand the product lines and is committed to manufacturing and supplying iron and steel castings made by various casting methods, forgings and profile machined parts.
Get a Quote| Item | Description |
|---|---|
| Material Standard: | GB.ASTM.AISI.DIN.BS.JIS.EN.AS.AAR. |
| Max linear Size(W*C*H): | 1200mm*800mm*650mm |
| Min thickness: | 6mm |
| Casting Weight Range: | 0.5-100Kgs |
| Casting Dimension Tolerance: | CT8 |
| Casting Surface Roughness: | Ra12.5-25um |
Qianhao Group offers tailored shell molding casting solutions to meet diverse requirements, providing one-stop services from mold preparation to precision finishing.
Small batches of shell molded castings can be delivered in 15 days, large batches in 30 days, and urgent orders can be expedited to help you meet critical project timelines.
We provide complete shell molding services, from mold design and shell preparation to metal pouring, heat treatment, and precision finishing, ensuring consistent quality for complex parts.
Our shell molding casting service achieves high-precision tolerances, typically ±0.1mm, suitable for aerospace, medical, automotive, and industrial applications requiring complex metal components.
Qianhao is a globally recognized manufacturer of high-valued added and complex castings for global industry leaders