Cores & Molds

Green Sand Casting
Green sand undergoes a "mulling" process in which water and clay act like binders, and are blended with sand resulting in a compound mixture which is suitable for the green sand molding process. The sand is rammed, compacted, and squeezed around a pattern by one of our green sand molding machines.

Our green sand casting molding equipment consist of:
Osborn Squeezer machines which hold flask sizes ranging from 12” x 12” to 18” x 18”.
Osborn Cope and Drag machines which hold flask sizes of 16” x 16” to 30” x 30”.

Airset Molding
Airset molding, also referred to as “No Bake”, is one of the most efficient and advanced sand casting molding techniques available. It offers dimensional stability and a clean surface finish. This molding line is used for large castings and castings with highly complex geometry. No Bake is a bonding process using dry sand mixed with a 3 part Phenolic Urethane Resin binder. The sand mixture sets hard in a short time and the mold can be removed from the pattern in less time. Our large floor (airset) line will hold flask sizes ranging from 24” x 24” to 120” x 120”.

Sand for Producing Molds
The key to every good green sand casting and airset casting is using a high quality sand. Sawbrook Steel is strictly a sand casting foundry and we acknowledge how imperative it is that we have clean, bondable sand. Strict control is kept on our sand systems and extensive testing is done to maintain consistency. Sawbrook Steel offers two types of sand molding, green sand casting and No Bake molding. Sawbrook takes extreme care in the making of cores and molds to assure good surface finish and correct dimensional control. Cleanliness, proper dryness, permeability and hardiness of the cores and molds are carefully monitored.