Iron Casting Methods – Green Sand, Resin Sand & Shell Molding
Proven Iron Casting Methods for OEM Parts
At TXMETAL, we specialize in three proven iron casting methods—green sand casting, resin sand casting, and shell molding casting—to produce high-quality gray iron, ductile iron, and ADI components. Our ISO 9001:2015 certified foundry combines cost efficiency, precision, and durability to meet the demands of global OEM projects.
Green Sand Casting – Cost-Effective Molding for Complex Shapes
Green sand casting is the most widely used method for producing complex and durable components at competitive costs. The mold is made from a mixture of silica sand, clay, and water, offering flexibility for various part sizes.
Applications:
- Brake drums, hubs, and flywheels
- Agricultural machinery parts
- Pump housings and gearboxes
Advantages:
- Good surface finish and machinability
- Low tooling costs
- Fast prototyping and production
Resin Sand Casting – Precision Molding for Large & Heavy Castings
Resin sand casting uses sand coated with a resin binder, allowing stronger molds and improved dimensional accuracy compared to green sand casting. It’s suitable for large castings and components requiring higher precision.
Applications:
- Large machine bases
- Industrial pump casings
- Complex agricultural components
Advantages:
- Ideal for medium to large production runs
- Stronger mold structure for heavy parts
- Better surface quality than green sand
Shell Molding Casting – High Accuracy for Thin-Wall & Complex Parts
Shell molding casting (also known as shell mold casting) uses a heated metal pattern to form thin, strong, resin-coated sand shells. This method achieves excellent dimensional tolerance and surface finish, making it ideal for ductile iron and ADI components.
Applications:
- Thin-wall ductile iron castings
- Exhaust manifolds and flanges
- Hydraulic cylinder mounts
Advantages:
- Excellent repeatability for mass production
- High-dimensional accuracy
- Minimal finishing required
Choosing the Right Iron Casting Methods for Your OEM Project
Selecting between green sand, resin sand, and shell molding depends on:
- Part complexity and precision needs
- Production volume
- Material specifications and mechanical requirements
Our engineering team will recommend the most cost-effective process for your OEM project.