Shell Casting
Shell Casting Manufacturing: High Precision Solutions
Shell casting is a metal casting process utilizing thin, hardened sand/resin shells as molds. The process involves coating a heated metal pattern with a mixture of fine sand and thermosetting resin, creating a thin shell mold (1/4″ – 3/8″) that produces parts with excellent dimensional accuracy and surface finish.
Shell Casting Process
Sand/resin mixture bonded to pattern
Thin shell molds (1/4″ – 3/8″)
Excellent dimensional accuracy
Superior surface finish
Shell Casting Applications
- Automotive components
- Machine parts
- Valve bodies
- Pump housings
- Power transmission parts
Shell Casting Specifications
Weight range: 0.5-100 lbs
Tolerances: ±0.010 inch
Surface finish: 125-250 RMS
Wall thickness: 0.125″ minimum
Shell Casting Materials
- Gray iron
- Ductile iron
- Carbon steel
- Stainless steel
- Alloy steels
Shell Casting FAQs
What is shell casting's advantage over sand casting?
Better surface finish, tighter tolerances, thinner walls possible
What production volumes work best?
Medium to high volumes (5,000+ pieces annually)
What materials can be shell cast?
Most ferrous metals including iron and steel alloys
How does shell casting affect tooling costs?
Higher initial tooling cost offset by reduced finishing requirements
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