7. Metal mold casting

In the sand casting processes studied above, molds and cores have to be rebuilt after each pour, which poses numerous problems and requires extensive facilities for the production of new molds and numerous handling operations. It can be estimated that the production of one tonne of good cast-iron parts requires, on average, the handling of 20 tonnes, or even 50 tonnes and more for thin parts.

This production of molds leads to high consumption of new sand, with problems of disposal and landfilling of used sand when the recovery processes for old sand do not allow 100% recycling.

For this reason, we have always endeavored to produce molds or mold parts capable of withstanding several successive pours (molds made of cut stone, wood, cast iron, etc.).

This idea is very old, but the process was not developed industrially...