Aluminum Sand Casting DCPD Molds

Plus stock CNC machined sand castings can take a good deal of costs out of the DCPD tooling budget. Castek’s tight grain structure enhanced metal handling processes on our aluminum castings allow us to provide a much lower cost alternative to aluminum billet DCPD molds. Castek CNC machines a core and cavity foundry pattern, manufactures aluminum castings with machining stock and then CNC machines and assembles the mold complete. Each Castek aluminum sand casting DCPD mold has proper engineering, ribs and back side supports for durability and longevity.

CNC machined aluminum castings can be used in many development or non-cosmetic applications. Castek often times uses CNC machined aluminum castings for core side or back side of part mold halves coupled with a billet aluminum lower. This allows a significant cost savings on the core mold half. The lower side cavity is CNC machined from M1 or 5000 series aluminum to provide a “class A” surface. This mold type can save an even more substantial amount of tooling dollars on part geometries that an extend Z height.

Why use aluminum castings rather than aluminum billet?

  • Castings can be a much more economical option for larger molds and molds that have a deep draw (tall Z part height). Aluminum sand castings can weight a fraction of billet aluminum molds thus allowing easier handling for our customers.
  • Aluminum billet molds used in molding operations require gun drilling for temperature control. This gun drilling operation can add significant costs and additional labor to the mold. When using aluminum castings there is no need for gun drilling. The stainless-steel tubing is cast onto the back side of the aluminum castings to provide this needed processing control.
  • When using aluminum castings there is a significant savings on CNC machining hours. Castek “over casts” the mold face by and can immediately begin finish CNC programs as opposed to heavy roughing passes that are needed on billet aluminum molds.
  • Aluminum castings can save a great deal of project timing. On larger molds often times the billet aluminum producers have long lead times or may not be able to produce a billet of that particular size. Castek has several large foundry flasks to form the sand molds around your project and can custom manufacture a foundry flask to allowing molding these larger projects. This coupled with reduced CNC machining hours when using sand castings can reduce many weeks of overall program timing for your project.