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Superior Aluminum Foundry Solutions
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Foundry Services


The plaster mold casting process uses a combination of molding plaster and hot water to form a clean, smooth, detailed casting. When compared to sand casting processes, plaster molding allows for tighter tolerancing, minimal wall thicknesses and smooth aesthetic surface finishes. This process is ideal for your more intricate and/or thin-walled castings.

Plaster Molding for Precision Prototype Production

Using the plaster mold casting process will allow you to prove the design characteristics of your part and/or enable modifications quickly and inexpensively. The plaster mold casting process is an excellent bridge to high-volume production processes. Quickly get your prototypes in hand so that you can make internal design refinements and/or get a headstart on your product marketing campaigns.

Plaster mold casting can also be used for a permanent low-volume production, yielding up to 2000 parts per year. Many benefits including, but not limited to: low tooling costs, smooth surface finish, thin-wall capabilities (as low as .080”), and exceptional detail.

K&H Precision Products, Inc. takes pride in our state-of-the-art foundry. We have two complementary manufacturing departments dedicated to the plaster mold casting process and sand casting process. We also offer a hybrid process involving both casting methods.

We are a gravity-fed aluminum foundry pouring multiple aluminum alloys with the capability of pouring zinc. All of our casting services are backed by our ISO 9001:2015 certified quality management system.

The Advantages of K&H Precision Products Foundry Division

Multiple molding medias allowing varying wall thicknesses (.080” and up)

Streamlined pattern shop to foundry allowing for better communication and lead times

Core-making in-house

Firm focus in quality and customer service with years of invaluable experience


The no-bake sand mold casting process is an age-old manufacturing procedure preserved in its purest state. Over the years, sand casting has evolved in several directions along with new technological innovations. At K&H Precision, we use fine no-bake sand and a urethane binder enabling us to expand to a broader range of production capabilities.

The Benefits of the Sand Mold Casting Process

  • Closer tolerance than other sand mold casting processes (see chart in technical specs)
    Ability to cast wall thicknesses from .187″ and up
  • A better surface finish than typical in sand casting: 200-500 micro-inch finish
  • More complex geometry than traditional oil-bonded sand castings

Streamlined Sand Mold Casting Capabilities Optimized for Low-Volume Production

The fine no-bake sand mold casting process is best suited for regular and thicker wall thickness. It is a great tool for prototyping permanent mold applications. K&H is able to offer very short lead times for prototypes and low-volume production castings (up to 3000 parts per year).


Our hybrid mold casting process is a combination of sand mold casting and plaster mold casting. Our optimized hybrid molding capabilities enable us to manufacture a wider range of parts with superior surface finishes and lower porosity, especially when dealing with varying wall thicknesses.

Hybrid Molding Solutions Optimized for Complex Component Geometries

The hybrid casting process is best suited for irregular wall thicknesses that require a cosmetic product finish along with internal metal integrity. One side of the finished component will have a plaster mold finish, while the other side, or core area, is sand molded. This optimized hybrid mold casting process is a great compromise for parts and prototypes with difficult casting geometries.


Adaptability to work with varying wall thicknesses

Ability to cast wall thicknesses from .093″ to .500″

A better surface finish one side of the part, fine sand finish on the opposite side

More complex geometry than traditional oil bonded sand

Lower porosity and general better metal quality than if the Plaster Mold casting process was used alone


  • Complete in-house Foundry
  • Daily Casting Alloys: A – 319, 355, 356, 380
  • Others: ZA – 3, 5, 12
  • Rotary De-Gassing
  • Calibrated Pyrometers
  • (4) 450 lb Crucible Furnaces
  • (1) 1100 lb hydraulic tipper Crucible Furnace


  • Custom prototype design and manufacturing
  • EAU – 5-3000
  • Kan-Ban available upon agreement
  • Custom prototype design and manufacturing
  • EAU – 5-3000
  • Kan-Ban available upon agreement
  • Work direct with the production process to give a seamless prototype-to-production experience

Free Concept Evaluation

Fill out K&H’s free evaluation and see what we can do for your company.