Choose Your Casting Method

Below are brief descriptions of the capabilities of the Eagle Group, including several different methods of metal casting, as well as CNC machining. We hope to help you choose the metal casting method that’s right for your project. Take a look at our resources below, and if you have any questions click here to contact us any time.

Shell mold process

Offered by Eagle Alloy, the shell mold process is the industry standard for medium to high volume, commercial-grade casting projects. For a better look at how the process works, we offer a video animation and a comprehensive white paper on shell mold casting.

Thermally bonded sand is applied to the surface of a pre-heated pattern usually made of cast iron or steel. The “baked” mold is lifted from the pattern in halves. The halves are glued together, assisted by precise locating features to avoid shifting. The Shell process offers tolerances of +/-.030” on dimensions 6” or less and a surface finish around 200 – 250 RMS. Click here for a complete description of available tolerances, radii, fillets and other design considerations.

Advantages: good casting detail, excellent repeatability, very productive, less machine stock required than in greensand or no-bake processes, competitive pound-prices, very short production lead times.

Disadvantages: tooling prices higher than some other processes.

Click below to learn more about shell molding:

Lost-wax investment casting process

Eagle Precision Cast Parts uses this process exclusively. Wax is injected into an aluminum die to create a wax “pattern”. These wax patterns are then assembled onto a “tree” which is repeatedly dipped in a ceramic slurry that, after drying, hardens into a mold. The wax is melted out, the mold is preheated and the metal is poured in. The resulting casting has an excellent surface finish of around 125 RMS, crisp lettering and minimal machine stock. This process is perfect for highly visible parts or replacing machining with cast features. Tolerances can be held to +/-.005” in most cases.

Advantages: excellent overall appearance, machining reduced or eliminated, can cast very thin walls, good for prototypes, economical tooling costs.

Disadvantages: higher pound-prices.

Click below to learn more about the investment casting process:

CNC machining

Different metal casting methods are ideal for different applications, but CNC machining is often the final finishing process.

Eagle CNC Technologies utilizes the latest in machining technologies and has experience machining all types of casting and wrought materials. Our services are mainly utilized by, but are not restricted to, the Eagle Group. Our commitment to maintaining available capacity means our facility list is constantly expanding with the latest and greatest machines available. Contact us to discuss your next machining project.

Click below to learn more about Eagle CNC’s machining capabilities: