Shell Mould Casting

Best suited for thin-walled products with high-quality surface finish requirements, as the process gives a better surface finish and closer tolerances than sand casting.

Part of Your Prototyping Process

In the shell mould casting process, fine sand is poured on a heated metal pattern.

The hot surface of the metal hardens the resin-bonded sand to create a shell.

The shell is lifted off the model and glued together with the other half of the shell to create a sand mould. Then molten metal is poured into the shell sand mould.

Fine finish and close tolerance

Shell mould casting is best suited for thin-walled products with high-quality surface finish requirements, as the process gives a better surface finish and closer tolerances than sand casting.

The surface of the casting is processed to be quite similar to a pressure die cast one, and high accuracy of dimensions can be achieved through additional machining.

The method may be combined with the use of sand cores to make even more complex structures. It is possible to cast thin walled products at close tolerances. The initial tooling cost is higher than for sand casting.

Part of Your Prototyping Process

The shell mould casting method is well applicable in pre-series of pressure die cast components. Shell mould casting is suitable when changes during the product development phase need to be implemented easily and quickly.

The method is best suited for prototyping and as a part of our client’s product development processes. In some processes, the correct format for the aluminium part is sometimes finalized through prototyping.

Shell mould casting may also be used for manufacturing the actual parts, but as the moulds are not reusable, the method is not ideal for mass production.

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