Foundry

K&H Precision Products, Inc. takes pride in our Foundry. We have two complementary departments in the Plaster Mold Casting process and Sand Mold Casting process. We are a non-ferrous foundry; pouring Aluminum Alloys with the capability of pouring Zinc.

Plaster Mold Process

The Plaster Mold casting process is a gravity fed method in which you use a combination of molding plaster and hot water to form a clean, smooth, detailed casting. This process, unlike sand mold casting processes, allow for tighter tolerancing, minimal wall thicknesses, and smooth surface finishes. This process is ideal for your more intricate or thin walled castings. As previously stated, there are several advantages to the plaster mold casting process including:

  • Closer tolerance parts (see chart in technical specs)
  • Ability to cast wall thicknesses as thin as .080"
  • Yields greater definition of detail
  • Leaves a smooth surface finish similar to die casting 90 - 120 micro inch finish

Using the Plaster Mold Process for prototyping will allow you to prove design characteristics of your part and/or enable modifications fast and inexpensively. The process is an excellent bridge to high volume die casting production by giving you parts in hand for internal process refinements, and product for marketing. Plaster Mold process can also be used for a permanent low-volume production (up to 1500 parts per year) application with a low tooling price and a life of product guarantee on your tooling.

To sum up the advantages; no surprises, no delays, this quick design-product process allows you to have a prototype in as little as 6 weeks. Don’t have funds tied up with drawn out project – build your confidence of your end result prior to production.

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Plaster Mold Casting

Sand Mold Casting

The Sand Mold casting process is an age-old process in its purest state. Over the years it has morphed in several directions. At K&H we use fine no-bake sand and a urethane binder giving us the ability to expand to a broader range of possibility in process typical parts.

  • Closer tolerance than other sand mold processes (see chart in technical specs)
  • Ability to cast wall thicknesses as from .125" & up
  • A better surface finish than typical in sand casting: 250-500 micro inch finish
  • More complex geometry than traditional oil bonded sand

Using 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 3500 parts per year).

sand mold casting operation

Sand Mold Casting

Hybrid Mold Casting

Our Hybrid Mold casting process is a combination of the Sand Mold casting process and Plaster Mold casting process. This enables a wider range of parts to have better surface finish and lower porosity when dealing in a thick metal application.

  • Adaptability to work with varying wall thicknesses
  • Ability to cast wall thicknesses as from .093" - .500"
  • A better surface finish one side of 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

Using the Hybrid Casting Process is best suited for irregular wall thickness with need for cosmetic outside look and internal metal integrity. One side of the part will have a Plaster Mold finish while the other side or core area would be Sand molded. It is a great compromise for difficult casting geometries.

hybrid mold casting

Hybrid Mold Casting

Casting

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

Prototype to Low-Volume Production

  • Prototypes
  • EAU – 5-3000
  • Kan-Ban available upon agreement
  • Work direct with production process to give a seamless prototype to production experience