At KPMC, we specialize in permanent molds and semi-permanent molds for mold casting processes including prototype, production-intent development, and production tooling. Our permanent mold expertise includes gravity and low-pressure molds including counter pressure and vacuum assist for low-pressure molds. Our tooling includes solutions for aluminum and magnesium castings for complex high performance products used in automotive, truck, heavy equipment, construction, military, aerospace, beverage equipment and other advanced manufacturing industries. From cylinder heads, cylinder blocks, wheels and suspension components to military and aerospace components to construction brackets and cooling plates, we understand your business and the permanent mold processes that ensure quality castings.

Permanent Mold Processes and Casting Specifications

Processes

·         Gravity Permanent Molds

·         Low-Pressure Molds

·         Counter Pressure for Low-Pressure Molds

·         Vacuum Assist for Low-Pressure Molds

·         Semi-Permanent Molds

·         Tilt-Pour

Alloys/Metals

·         Aluminum

·         356-T6

·         355-T6

·         319-F

·         357-T6

·         Magnesium

Castings Range:

·         Ounces to 300 lb. Castings

Industries Served:

·         Automotive, Trucking, Racing, Beverage Equipment, Construction, Heavy Industrial Equipment, Material Handling Equipment, Military, Aerospace

Permanent Mold Advantages

·  Facilitates High Volume Casting

·  Large Production Runs Reduce Manufacturing Costs

·  Product Tensile Strength

·  Products have Excellent Mechanical Properties.

About Permanent Mold Casting

Permanent mold casting molds are preheated and thermal temperatures are maintained as molten aluminum and magnesium alloys are poured over patterns to shape the product. Once the mold is set, the pattern is drawn out to reveal the coarse mold cavity to be machined and made smooth. In the gravity permanent mold process, metal flows using the force of gravity by either static pouring (from the top) or tilted pouring using a basin with the mold on a slant. Gravity permanent molds produce more accurate castings than shell mold castings. In the low-pressure permanent mold process, low-pressure forces push metal into the mold. Low-pressure permanent molds produce uniform castings with excellent dimensional accuracy, perfect surface finish and superior mechanical properties.