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Engel Injection Molding Machine | Ductile Iron Parts Cooperation Case

Leveraging its mature resin sand and coated sand casting processes, Keboer Group has successfully established a partnership with Engel Injection Molding Machine, a world-renowned enterprise.

Machine Tool Casting Components

Discover the essential casting processes for machine tools. Learn why Resin Sand is best for large beds and why Coated Sand is superior for spindle boxes and motor seats.

How to Choose a Reliable Cast Iron Foundry

Ultimate Guide – 5 Core Criteria + Supplier Evaluation Form In the field of industrial manufacturing, the quality of cast iron parts directly determines the stability and service life of equipment. Choosing a reliable foundry is the first and most critical line of defense to ensure casting quality.

Resin Sand Casting vs Coated Sand Casting：Choose the Right Casting Process for Cast Iron Parts

Resin Sand Casting vs. Coated Sand Casting: Choosing the Right Process for Cast Iron PartsIn the competitive world of iron foundries, selecting the right molding process is paramount. It directly dictates the precision, surface finish, and production efficiency of your castings. While both Resin Sand Casting and Shell Mold Casting (using Coated Sand) utilize resin as a binder, their production methodologies, outcomes, and ideal use cases are fundamentally distinct.1. Resin Sand Casting ProcessMixing: Raw sand (e.g., silica) is thoroughly mixed with liquid resin (furan or phenolic) and a curing agent (acid catalyst).Ramming: The mixture is filled into molds (wood, plastic, or metal patterns) and compacted pneumatically or hydraulically.Curing & Stripping: The sand cures at ambient temperature via chemical reaction, after which the mold is stripped.Core Setting & Closing: Cores are placed, and the mold is closed for pouring.Pouring & Shakeout: After pouring molten iron, the casting cools (12-72 hours), then is extracted via a shakeout machine.Inspection: Critical checks for roughness, dimensions, and mechanical properties are conducted.Resin sand casting - wooden moldResin sand casting - Sand shellKey Outcomes & ConsiderationsDimensional Accuracy: High (Grade CT9-CT12), better than green sand but less than shell molding.Surface Quality: Good (Ra50-Ra100), though minor sand adhesion may occur.Efficiency: Moderate. Curing time limits line speed.Best ApplicationsIron Casting Types: Machine tool beds, housings, columns, worktables.Scenarios: Large/medium castings, single-piece or small-batch production.→ Click to view this tech’s production process2. Coated sand shell castingShell molding utilizes heat to activate the binder for superior precision.Coating: Sand is pre-coated with thermoplastic phenolic resin and a hardener (Hexamine) at the supplier's facility.Shooting: The coated sand is shot into a heated metal die (180°C - 250°C).Heat Curing: The sand forms a thin, hard shell as the resin melts and cures upon contact with the hot pattern.Ejection & Assembly: The shell is ejected, assembled, and placed in a flask.Pouring: Molten iron is poured directly (approx. 1400°C). The shell has high hot strength.Knockout & Finishing: After cooling (7-24 hours), the box is opened for finishing.Inspection: Critical checks for roughness, dimensions, and mechanical properties are conducted.Coated sand shell casting - iron moldCoated sand shell casting - sand shellKey Outcomes & ResultsDimensional Accuracy: Very high (Grade CT7-CT9), with excellent repeatability.Efficiency: Very high, ideal for automated mass production.Best ApplicationsIron Casting Types: Engine blocks, cylinder heads, gear housings, precision valves.Scenarios: High-volume production, precision castings, complex internal cavities.→ Click to view this tech’s production process3. Core Comparison SummaryFeatureResin Sand CastingCoated sand shell castingHardening PrincipleChemical Reaction (Room Temp)Thermal Activation (Heated Mold)Pattern MaterialWood, Foam, AluminumIron/Metal Only (Heat Conductive)Production EfficiencyModerateHigh (Fully Automated)Surface FinishGood (Ra50-Ra100)Excellent (Ra25)Primary CostMaterial & RecyclingMold Cost, Energy & MaterialTypical UseHeavy Machinery, Large PartsAuto Parts, Precision BlocksResin sand process cast iron castingsCoated sand shell casting Prats4. How to Choose for Your Iron Foundry Project?Choose Resin Sand Casting if...You produce large or medium-sized castings.Production volumes are low to medium.You need cost-effective wooden patterns for prototyping.Cost Note: While tooling is cheap, per-unit costs for high-appearance parts can be high.Choose Coated sand shell casting if...You require high precision and smooth surfaces.You are running high-volume batches (e.g., gearbox castings).You can afford the initial investment in metal tooling.Cost Note: 15% lower cost than resin sand for mass production, but 30% higher for small batches.ConclusionUltimately, the choice between these two processes hinges on a balance of part size, production volume, and budget.Resin sand casting offers flexibility and lower initial tooling costs, making it the "economy workhorse" for heavy sections.Conversely, Coated sand shell casting is the "precision specialist," delivering superior surfaces and lower per-unit costs in high-volume scenarios despite higher tooling expenses.Ready to Start Your Casting Project?Get expert advice on the best casting process for your specific iron parts. Our engineers are ready to provide a detailed quote and technical support.Request a Quote NowEmail: keboer@kbrcasting.comWhatsApp: +86 18621536837

5 Core Factors Affecting Custom Cast Iron Parts Pricing

5 Core Factors Affecting Custom Cast Iron Parts Pricing: A Buyer's Guide to Avoid PitfallsIn the procurement of custom cast iron parts, price fluctuations often make it difficult for buyers to control accurately — for the same custom cast iron mechanical component, quotes from different cast iron manufacturers can differ by more than 30%.In fact, the pricing of custom casting parts is not arbitrary. It is jointly determined by five core factors. This article will break down the impact logic of each factor, helping you understand pricing rules and avoid hidden charges.I. Material Cost: The "Basic Anchor" of PricingMaterial is the core premise. Differences in composition and performance directly determine raw material costs, which is a primary source of price differences.1. Material Type Dominates the Cost BenchmarkCommon materials include Gray Cast Iron (HT200, HT250, HT300) and Ductile Iron (QT400, QT450, QT500).Price Trend: Ductile Iron > Gray Iron > Ordinary Gray Iron.Market Insight: In 2026, the raw material price of ductile iron is 20%-35% higher than gray iron because it requires alloying elements like magnesium and rare earths.2. Performance Requirements Drive PremiumsExample: Upgrading from QT450-10 to QT600-3 involves optimizing chemical ratios, increasing raw material loss by 8%-12%, and raising testing costs. The final unit price may rise by 15%-20%.3. Purity and Environmental StandardsEco-friendly materials: Meeting RoHS or ultra-low emission standards requires high-quality scrap steel (low sulfur/phosphorus), increasing costs by 10%-15%.High-end Purity: For medical or machine tool applications (99.9% purity), additional purification processes significantly push up costs.II. Mold Complexity: The One-Time InvestmentMost custom parts require exclusive molds. The design and material of the mold determine the initial investment.1. Structure Design DifficultySimple Structure: Flat plates or cylinders (e.g., bases). There are no complex separation surfaces(About 1 ton), Mold cost: 1000-3000USD.Complex Structure: Deep cavities, special-shaped holes (e.g., engine blocks). Requires multi-component parting and slider core-pulling. Mold cost: 2000-10,000USD.2. Mold Material and Service LifeMold MaterialTypical LifespanCost ImpactWooden Mold500 timesLow (suitable for prototyping)Aluminum Mold5,000 timesMediumCast Iron Mold100,000+ timesHigh (suitable for mass production)3. Modification and OptimizationThe larger the batch, the lower the fixed costs (equipment commissioning, labor) allocated to each product.Resin Sand Process - Sand Shell↗️Coated Sand Process - Sand Shell↗️III. Order Quantity: Key Variable for Cost AllocationThe larger the batch, the lower the fixed costs (equipment commissioning, labor) allocated to each product.Small Batch (10-500 pcs): High allocation of mold fees. Scrap loss rate can reach 20%-30%.Medium Batch (500-5,000 pcs): Unit price is typically 5%-15% lower than small batches as economies of scale appear.Large Batch (>5,000 pcs): Continuous production reduces raw material loss to under 10%. Tiered pricing discounts often apply.💡 Pro Tip: Pay attention to the Minimum Order Quantity (MOQ). Orders below the MOQ (usually 10-100 pieces) may lead to significantly higher quotes or refusal to produce.IV. Processing Allowance: Cost for PrecisionProcessing allowance is the metal cutting amount reserved after casting. Higher precision equals higher costs.1. Core Impact LogicSmall Allowance (1-2mm): For low-precision parts (brackets). Low material loss (5%-8%).Medium Allowance (2-5mm): For gears, pumps. Requires turning, milling, and drilling.Large Allowance (>5mm): For machine tool beds or precision instruments. High material loss (10%-20%) and expensive CNC time.2. Tolerance RequirementsStricter tolerances (e.g., ±0.01mm) require larger allowances to ensure the final dimensions are met. This can make the unit price 15%-25% higher than standard parts.Rough Casting: Before Processing↗️Finished Part: After Precision Machining↗️Buying Guide: How to Optimize Your CostsAvoid "Over-Customization": Don't specify high-end alloys or ±0.01mm precision if standard grades and ±0.5mm work for your application.Integrate Batches: Combine several small-batch needs into one medium-batch order to reduce unit costs.Confirm Mold Ownership: Ensure you own the mold so it can be reused for future orders without repeated fees.Verify Quote Composition: Request a breakdown (Material, Mold, Machining, Surface Treatment) to avoid hidden charges.📩 Get Your Custom Cast Iron Parts Quote NowNeed precise project cost analysis? Our engineers optimize casting for better pricing.

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News & Blogs

Engel Injection Molding Machine | Ductile Iron Parts Cooperation Case

Machine Tool Casting Components

How to Choose a Reliable Cast Iron Foundry

Resin Sand Casting vs Coated Sand Casting：Choose the Right Casting Process for Cast Iron Parts

5 Core Factors Affecting Custom Cast Iron Parts Pricing

Email

Phone / WhatsApp

Shanghai Office

Anhui Factory

Capabilities

VMC Casting Solutions

Application

About Keboer

Resource

CONTACT US

ARBURG uses cookies

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