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Custom Metal Casting Molds

Benefits of Custom Metal Casting Molds

Today, the demand for high-quality custom metal parts is high. Custom metal casting molds enable customers to obtain a diverse array of customized parts cast in desired metals and metal alloys. The largest benefit of having custom molds is that they permit repeated use. They make it possible to create a high volume of various parts at a fraction of a price. 

We can assist your enterprise in crafting high-quality metal parts cost-effectively using customized metal casting. Our capabilities include a variety of metal and metal alloys, and we will furnish excellent custom metal casting molds according to your requirements. 

 

Custom Casting Mold Types

Custom metal casting involves the use of either temporary or permanent molds. In most cases, our customers will select permanent molds in order to re-use the mold whenever they need to create multiple copies of a customized item. The main difference between temporary and permanent molds is their reusability. 

  • Temporary Molds: Temporary molds generally do not survive the casting process in a condition allowing re-use. Sand molds illustrate one popular type of temporary mold.
  • Permanent Molds: Manufacturers usually create permanent molds in order to obtain reusable casting components. Graphite, stainless steel, and steel illustrate three popular permanent mold making materials today. While these molds will eventually wear out, of course, they last longer than temporary molds. Customers seeking customized molds frequently choose to invest in high-quality permanent molds in order to produce multiple copies of identical parts.

 

Creating Fine Custom Metal Casting Mold

The permanent metal mold casting process generally involves at least six separate steps: 

  1. A manufacturer first carefully crafts a permanent mold using a material selected by the customer. The nature of the metal alloys used in the cast product generally determines the type of material employed during mold construction. 
  2. During the mold-making process, a manufacturer must carefully measure and tool the parts of a permanent mold to ensure they fit together tightly. The design team creates gates to permit the entry of molten metal; it also engineers a “sprue”, a hole allowing for the entry of the hot metal through the gate. The permanent mold normally also provides channels for venting gases.
  3. In many cases, permanent molds require the force of gravity to allow molten metal to fill the mold. A manufacturer must supply a way to melt metal alloys and then load this molten material into the mold safely.
  4. By preheating and lubricating the permanent metal mold, the manufacturer helps ensures smoother filling. The manufacturer also secures mold parts together tightly (frequently with the aid of machinery). This operation occurs in a high-temperature environment, so automation helps to fasten the heated mold components. After assembling the mold, the manufacturer pours molten metal through the sprue into the gate. In some cases, automated centrifugal forces help disseminate metal through the mold more completely; in other cases, gravity alone assists this mold filling process. After completing the filling operation, the manufacturer allows the metal to partially cool and solidify inside the mold.
  5. Eventually, the manufacturer unfastens the mold (generally with the assistance of ejector pins).
  6. Final cooling occurs before finishing operations commence.

 

Essential Mold-Making Requirements

The custom metal casting process at a minimum requires a mold tailored to meet a client’s specifications, and the capability to melt and pour metal alloys into the custom mold. A design team carefully crafts temporary or permanent molds according to the client’s directions. While manufacturers sometimes use temporary molds, such as molds made from sand or plastic, customized molding more often involves the creation of permanent, and therefore reusable molds. Customized metal casting usually occurs at comparatively high temperatures.

The metals used in any custom metal casting project largely determine the types of materials required for use in permanent casting molds. Frequently, manufacturers cast industrial components using molds made from graphite, ceramic, or stainless steel. A permanent, reusable mold must typically remain capable of withstanding the heat generated by molten metal without changing its shape, shattering, bending, or dissolving. The intended casting method, e.g. whether a manufacturer uses injection molding or gravity casting, may also enter into the choice of the materials required during mold construction.

 

The Benefits of Using Custom Cast Components

Using custom cast components created with custom metal casting molds certainly offers many benefits:

  • All components will be created according to specifications
  • The size is more accurate than with traditional forging and welding processes
  • There’s less stress involved in the process
  • Higher quality end product
  • Shorter production time
  • Less power consumption
  • Efficiently used materials (no cropping or drops)
  • Automated production options
  • You can opt for the creation of custom metal molds that can be reused in case you need more component

 

Why Customers Request Our Metal Casting Molds Process

The metal casting molds process used by Bunty LLC offers customers some important advantages.

  1. The use of a customized permanent mold allows us to create a wide variety of shapes, and to reproduce objects dependably.
  2. Using this casting process helps create metal products with stronger, more uniform interior structures.
  3. Custom metal casting allows the generation of items with ornate, finely detailed surface features.
  4. This manufacturing process holds economic benefits. While permanent molds will eventually wear out, they usually endure much longer than many other production tools. Relying upon permanent custom molds allows you to optimize your investment in a high quality mold over the course of time.

 

CONTACT BUNTY LLC TODAY

For further information about our custom metal casting molds and other capabilities, contact us directly via the convenient website form or request a quote here. We welcome your inquiries.