In Acme Foundry’s carefully controlled sand casting process, the quality and repeatability of the final product is established long before molten metal hits the mold.
As with virtually every manufacturing process, your end product quality is largely determined by the quality of the tools you employ. Which means with gray iron casting, one of the most critical aspects of the process is found in the core room. At the heart of our foundry, Acme’s core room is where we build precision sand cores, designed and fabricated to meet the exacting requirements of our customers’ complex cored castings.
For today’s foundries which produce a wide range of complex products, core making is not just a support function or a secondary service. It’s an integral step in the casting process that directly influences dimensional accuracy, internal geometry, surface finish, and structural integrity – especially as design complexity increases and tolerances become tighter. Tackling the core making process in-house allows Acme to ensure superior quality while keeping your project lean and cost-effective.
Manufacturing Complex Cored Castings
In gray iron casting, cores are used to create internal cavities or complex features that cannot be shaped using standard patterns alone. The Acme Foundry core room produces complex custom cores made from specially formulated sand mixtures bonded with various resins or binders, depending on the desired performance and application.
Producing custom cores in-house facilitates superior casting results for our customers:
- Accommodating casting complexity and design flexibility.
- Maintaining precise dimensional tolerances and repeatability.
- Achieving exceptional surface quality and machinability for custom-machined castings.
- Supporting overall production efficiency and minimum scrap rates within our foundry.
At Acme Foundry, our investment in advanced core-making technologies allows us to produce intricate, high-quality cores that support the production of castings for industries ranging from agriculture to industrial equipment.
Integrated Core Making and Sand Casting Processes
An often overlooked advantage of a well-managed core room is its close collaboration with the foundry’s other tooling and molding processes. At Acme Foundry, our engineering and tooling teams work closely alongside core design experts to ensure optimal core positioning, venting, and assembly.
Our careful integration of processes minimizes core shift, enhances metallurgical integrity, and helps reduce rework. For customers, it means reliable, high-performance gray iron castings delivered on time and to specification.
Quality American Core Making and Custom Casting Services Since 1905
Founded in 1905 in Coffeyville, Kansas, Acme Foundry is one of the nation’s longest-serving foundries specializing in the manufacturing and machining of gray iron castings. Our company has proudly remained one of the nation’s leading manufacturers of a wide range of custom castings for over 115 years through our superior quality, consistency, and customer service.