Size Doesn’t Matter: How we move beyond the norm
July 20, 2017


Custom Castings pushes the envelope of what we can do beyond the permanent mold industry norm.
When you’re looking into manufacturing larger than normal parts, your industry norm option is sand casting. While sand casting works, it comes with increased per-piece cost with a low production rate.
We’ve been manufacturing large parts using permanent mold since our inception and have only gotten better at doing so. We have the ability to produce permanent mold castings typically larger than what most permanent mold foundries are doing.
We’ve pushed boundaries and found new ways to manufacture larger castings year after year. Through learning and tweaking our process, we’ve been able to accommodate our customers’ needs while offering the benefits of permanent mold casting.


The misconception with permanent mold casting is its limitations in producing large castings, but we’ve found it’s due to tools and processes permanent mold foundries are typically casting with. While the majority of permanent mold castings are ~1-50 lbs, we do have the ability and experience to exceed those weight limitations and produce 200 lb castings using the permanent mold casting process.
In our experience, people choose sand casting by default just based off their misconceptions of permanent mold. As we stated, sand casting is fine, but it lowers your production rate and part quality.
Casting with permanent mold gives you the benefits that sand casting can’t touch. When our only limitation is equipment, we’ll customize or invest (as we’ve done in the past) in our equipment to meet client needs.


While altering current equipment or investing in new equipment certainly helps us produce larger castings, there’s more to it. Since scaling up our operations and casting sizes, we’ve had to rethink and customize our current processes to:

  • Remove large castings from the mold
  • Prepare large castings for secondary processes
  • Move a high volume of molten metal safely and quickly enough to prevent oxidation

As always, we’ve taken these challenges in stride for the improvement of casting quality and customer service.
We think about the benefits permanent mold offers in comparison to sand castings and we know taking the extra step is worth it to us and our customers.

CLIENT SUCCESS STORY: Before producing with permanent mold, one of our clients used a sand foundry to cast a 48” long part weighing 180 lbs. The foundry couldn’t keep up to demand nor could they consistently provide a quality part. Once the client finally received their parts, the part would break in the field and cause significant downtime and expense.
We knew this client needed high-quality, consistent casting production and we were confident permanent mold would deliver.
Since transitioning to permanent mold casting, we’ve been able to produce 10x the amount of castings than the sand foundry could with sand casting while maintaining high quality parts our client expects.


When you’re in the market for large castings, you’re not stuck with sand castings – you have options: permanent mold, to be exact.
Permanent mold is your answer if you need tighter tolerances, faster production rates, and high quality parts.

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