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Permanent Mold Castings

The permanent mold process is the closest process to die casting General Foundry offers and is used to create geometries needing increased structural integrity and intermediate to higher volumes. The permanent mold tooling is negative H-13 machined steel or cast iron and can offer the quickest cycle times, but the highest tooling costs. General Foundry utilizes tilt pour machines, reducing metal tumble during the pour. Coupled with preheated mold halves, permanent mold produces superior metal characteristics for increased volume applications. The thinnest wall section (geometry dependent) for a permanent mold casting is .187”. This process utilizes sand cores or metal pins, to create holes, hollow features or undercuts. The surface finish will be slightly better or similar to General Foundry’s green sand process, 125 RMS. 

The permanent mold process is as follows:

- create shell or CO2 sand cores
- pour metal into pour bowl (machine resting horizontally)
- machine tilts vertically
- gravity feeds molten aluminum into negative tooling
- metal solidifies, machine tilts back horizontally
- mold halve open and part is ejected with pins