Foundry Operations
Automated Molding for Consistent Production
Cast Products operates highly automated 32″ × 32″ and 20″ × 24″ flaskless molding lines supported by automated mold handling and integrated sand processing systems. These technologies reduce process variation, improve mold consistency, and support annual production volumes exceeding 1.3 million molds. Automated mold handling minimizes operator dependency while improving repeatability across both high-volume and complex production programs. The result is a stable manufacturing process capable of delivering consistent casting quality and reliable production performance.
Metallurgical Control from Melt to Pour
Consistent castings begin with disciplined melt practices. Our foundries utilize both gas-fired and electric melting systems with production capacity exceeding 5,000 pounds per hour, supported by inline degassing, precision grain refining, fluxing, and automated electromagnetic pouring technologies. These systems help maintain tight metallurgical control, reduce variability, and improve casting integrity throughout production. By controlling critical melt parameters, we produce aluminum castings with dependable mechanical properties and repeatable performance.
Advanced Sand System Technology
Our fully integrated sand processing systems, dedicated sand laboratory, and automated Hartley sand controls continuously monitor and maintain critical molding parameters. Through ongoing testing and process verification, we maintain consistent sand properties that contribute to improved dimensional accuracy, surface finish, and defect prevention. This disciplined approach helps ensure stable production and repeatable casting results across every program.
Data-Driven Process Control
Our investment in thermal analysis systems, process monitoring technologies, and expanding Industry 4.0 capabilities provides real-time visibility into key manufacturing processes. By collecting and analyzing operational data, we identify trends, reduce variation, and proactively address potential issues before they impact production. These systems support continuous improvement efforts while helping maximize equipment uptime, process stability, and manufacturing efficiency. The result is greater confidence in quality, delivery, and long-term program performance.
Built for Quality, Repeatability, and Scale
Every aspect of our foundry operation is designed to support repeatable manufacturing at scale. From automated molding and advanced melt control to integrated sand systems and real-time process monitoring, our technologies work together to create a highly controlled manufacturing environment. This approach enables us to produce complex aluminum castings with exceptional consistency, surface quality, and dimensional repeatability. Whether supporting new product launches or long-term production programs, our customers benefit from a foundry built around quality, reliability, and operational excellence.
Let’s Build Something Better
Talk to our team about your next aluminum casting project.