Shell Molding Services

Frigate employs shell molding for precise, high-strength metal components. Our process ensures superior surface finish and tight dimensional tolerances for complex geometries.

Our Clients

Advantages of Shell Molding Services

Reduced Casting Defects

The shell molding process minimizes common defects like porosity and shrinkage, ensuring better quality and consistency in parts.

Efficient Production

With shorter cycle times than other casting methods, shell molding offers high productivity and quicker turnaround times for large batches.

Dimensional Consistency

Parts made with shell molding exhibit excellent repeatability, ensuring consistent quality across multiple production runs.

Minimal Post-Processing

Shell molding's precision reduces the need for extensive post-casting machining, saving time and cost in finishing operations.

Custom Shell Molding Services for Precision and Durability

Custom shell molding provides high-precision, complex metal components with tight tolerances and superior surface finishes. This process is ideal for producing intricate geometries, ensuring consistent quality across large production runs. It accommodates various metals, including aluminum, stainless steel, and specialized alloys, offering flexibility for diverse applications. Shell molding minimizes the need for additional post-processing, reducing cost and production time. The result is durable, reliable parts that meet stringent performance requirements with excellent dimensional accuracy.

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Our Shell Molding Process

Material Selection

High-quality metal alloys are chosen based on the part's required strength, durability, and performance specifications.

Heating

The selected material is heated to a specific temperature, making it more malleable and easier to shape during the forging process.

Pre-Forming

The heated material is pre-formed into a rough shape using controlled pressure, closely matching the final part's dimensions.

Forging

The pre-formed material is then subjected to high pressure in a die, which shapes it to near-net dimensions, reducing material waste.

Cooling

The forged part is slowly cooled to ensure uniform material properties and to prevent distortion or cracking.

Finishing

To achieve the final shape, minimal machining or surface treatment is required, ensuring tight tolerances and high-quality surface finishes.

Post-Processing Services in Shell Molding

Post-processing in shell molding improves the quality and performance of cast parts, ensuring they meet industry standards. From heat treatment to surface finishing, these services enhance strength, precision, and durability.

Heat Treatment

Temperature: 900-1200°F
Time: 1-8 hrs

Aerospace (turbine blades), Automotive (engine components), Industrial (valves, pump components)

Surface Finishing

Ra: 1.6 to Ra 0.4 microns
Finish types: shot blasting, grinding, polishing

Automotive (brake discs, engine blocks), Aerospace (gearboxes, structural parts), Medical (surgical instruments)

Grinding

Tolerance: ±0.01mm
Surface finish: Ra 0.8-3.2 microns

Aerospace (critical components), Automotive (engine blocks, crankshafts), Industrial (precision parts)

Polishing

Surface finish: Mirror or Ra <0.2 microns

Medical (implants, prosthetics), Aerospace (turbine blades, rotor components), Jewelry (luxury parts)

Shot Peening

Intensity: 0.2-0.5 mmA
Coverage: 100%

Aerospace (engine parts), Automotive (suspension components), Industrial (high-strength materials)

Welding

Weld depth: 0.5-6mm
Process: TIG, MIG, Laser Welding

Automotive (chassis, exhaust parts), Aerospace (frame structures, engine mounts), Industrial (molds, frames)

Electroplating

Thickness: 5-50 microns
Material types: Nickel, Chromium, Gold

Aerospace (protective coatings on components), Automotive (chrome parts), Electronics (contacts, connectors)

Nondestructive Testing

Methods: X-ray, Ultrasonic, Dye penetrant
Sensitivity: 1-5% defect detection

Aerospace (high-stress components), Automotive (safety-critical parts), Industrial (pressure vessels, pipelines)

Machining

Tolerance: ±0.02mm
Surface finish: Ra 0.8-3.2 microns

Automotive (engine blocks, cylinder heads), Aerospace (mounting brackets), Industrial (gear shafts, rotors)

Coating

Thickness: 10-150 microns
Process: Electroplating, PVD, CVD

Aerospace (thermal barrier coatings), Automotive (corrosion resistance), Medical (biocompatible coatings, corrosion-resistant layers)

Methoding in Shell Molding

Core Material

Sand, ceramic, metal (inserts), or refractory

Aerospace (turbine blades), Automotive (engine components), Industrial (molds for complex parts)

Mold Type

Shell molds, expendable molds, reusable molds

Aerospace (high-precision castings), Automotive (gearbox, engine blocks), Industrial (large castings)

Pattern Material

Wax, metal, or plastic (depending on the alloy)

Aerospace (turbine engine parts), Automotive (engine heads), Industrial (precision tools)

Pouring Method

Gravity pour, centrifugal pour, vacuum pour

Aerospace (gas turbine blades), Automotive (suspension components), Industrial (pump bodies, valves)

Shell Thickness

1 - 10 mm

Aerospace (small, detailed parts), Automotive (suspension components), Industrial (valves, small casings)

Mold Hardness

50 - 60 HRC (depending on alloy and application)

Aerospace (critical engine components), Automotive (gearbox housings), Industrial (high-strength castings)

Pouring Temperature

600 - 1,500°F

Aerospace (turbine parts), Automotive (engine blocks), Industrial (high-performance materials)

Cooling Rate

10 - 300°C/min (varies by alloy)

Aerospace (fast cooling for precision), Automotive (gears, engine parts), Industrial (heavy-duty parts)

Pattern Removal

Wax removal (lost wax), sand blasting, or heating

Aerospace (turbine blades), Automotive (engine components), Industrial (complex shapes requiring precision)

Shell Strength

10 - 60 MPa

Aerospace (turbine blades, heat-resistant parts), Automotive (brake discs, engine components), Industrial (high-precision molds)

Shell Molding Materials

Shell molding is a precision casting process for complex, high-strength parts. It ensures tight tolerances and excellent surface finishes for demanding applications.

Aluminum Alloys

Commonly used for lightweight, high-strength components, aluminum alloys like 6061 and 356 offer excellent castability and corrosion resistance, which are ideal for aerospace, automotive, and consumer electronics.

Stainless Steel

Stainless steel grades such as 304 and 316 provide superior strength and resistance to oxidation and corrosion, making them suitable for marine, chemical processing, and high-temperature applications.

Copper Alloys

Brass alloys like C954 and C360 offer excellent wear resistance and conductivity. They are commonly used for components in electrical systems, plumbing, and heat exchangers.

Nickel Alloys

Inconel 718 and Hastelloy are known for their high-temperature stability, oxidation resistance, and corrosion resistance. These alloys are ideal for aerospace, turbine engines, and extreme-environment applications.

Tool Steels

High-carbon tool steels like D2 and S7 provide high wear resistance and hardness, making them ideal for manufacturing industrial molds and tools that undergo heavy stress and abrasion.

Titanium Alloys

Titanium alloys, such as Ti-6Al-4V, offer a high strength-to-weight ratio and excellent corrosion resistance, making them suitable for aerospace, medical, and marine applications where strength and lightweight properties are critical.

Precision in Handling High-Temperature Alloys for Reliable Performance

Shell molding at Frigate effectively addresses the challenges of working with high-temperature alloys like Inconel and titanium. Controlling the mold temperature and material flow ensures consistent material properties without compromising the integrity of the alloys. Advanced techniques prevent oxidation and minimize the risk of warping, even under extreme thermal conditions. This results in parts with high strength and durability, making shell molding an ideal solution for applications requiring reliable performance in harsh environments.

Compliance for Shell Molding Services

Frigate fully complies with industry regulations for our shell molding services. We follow strict quality control procedures and keep detailed documentation. Each phase of our process aligns with key certifications, ensuring top performance, safety, and environmental impact standards. We use data-driven methods and conduct ongoing monitoring to ensure continuous compliance with all necessary regulations.

ISO 9001:2015

Quality management systems for consistent product quality.

ISO/TS 16949

Automotive quality management standards.

ASTM B24

Standard specification for zinc and zinc alloys used in molding.

ISO 14001:2015

Environmental management system for reducing waste and energy consumption.

OHSAS 18001

Occupational health and safety standards ensuring a safe working environment.

NADCAP Certification

Aerospace quality certification for materials and processes.

REACH Compliance

Adherence to European Union regulations on chemical substances used in molding.

Tonnage in Shell Molding

Tonnage and capacity are key factors in shell molding, impacting the size, precision, and efficiency of cast parts. The table below highlights technical parameters and their applications in industries like aerospace, automotive, and industrial manufacturing.

Machine Tonnage

10 - 1,500 tons

Aerospace (turbine parts), Automotive (engine blocks, chassis), Industrial (high-strength castings)

Pouring Capacity

1 - 100 kg per shot

Automotive (engine components), Aerospace (structural parts), Industrial (valves, pump bodies)

Shell Wall Thickness

1 - 15 mm

Aerospace (precision turbine blades), Automotive (brake components), Industrial (molds, die-casting parts)

Mold Size

100 - 1,000 mm (diameter/length)

Aerospace (large frame components), Automotive (transmission cases), Industrial (large-scale molds)

Shot Weight

0.05 - 100 kg per mold

Automotive (suspension parts, gear components), Aerospace (critical engine components), Industrial (heavy-duty casings)

Casting Cycle Time

3 - 30 minutes per cycle

Automotive (mass production of engine components), Aerospace (low-volume, high-precision parts), Industrial (complex moldings)

Mold Temperature

500 - 1,200°F (depending on material)

Aerospace (high-performance materials), Automotive (heat-resistant components), Industrial (thermally treated castings)

Dimensional Accuracy

±0.01 - ±0.5 mm

Aerospace (tight-tolerance engine parts), Automotive (precision gearboxes), Industrial (critical tooling)

Mold Material Strength

10 - 60 MPa (depending on alloy and application)

Aerospace (turbine blades), Automotive (transmission parts), Industrial (tooling, dies)

Dimensions in Shell Molding

Dimensions play a critical role in shell molding, influencing the size, shape, and precision of cast parts. These parameters are essential for ensuring that components meet the exact specifications required across industries.

Maximum Mold Size

1,000 x 1,000 mm (L x W)

Aerospace (large structural parts), Automotive (chassis components), Industrial (large castings)

Minimum Wall Thickness

1 - 2 mm

Aerospace (small precision components), Automotive (brackets, gears), Medical (implantable devices)

Dimensional Tolerance

±0.01 to ±0.5 mm

Aerospace (engine components, turbine blades), Automotive (precision parts), Industrial (high-precision tooling)

Casting Weight

0.05 - 100 kg per part

Aerospace (critical parts), Automotive (engine blocks), Industrial (valves, pump components)

Max Single Shot Weight

100 kg

Automotive (engine components, suspension parts), Aerospace (turbine blades), Industrial (heavy-duty parts)

Mold Height

50 - 500 mm

Aerospace (turbo machinery), Automotive (suspension parts), Industrial (large equipment housings)

Casting Length

Up to 1,500 mm

Aerospace (landing gear), Automotive (long parts like axles), Industrial (large valves)

Casting Width

Up to 1,000 mm

Aerospace (frame components), Automotive (gearbox housings), Industrial (large machine parts)

Core Diameter

10 - 100 mm

Aerospace (turbine engine components), Automotive (exhaust manifolds), Industrial (core holes in castings)

Tolerance for Shell Molding Services

Dimensional Accuracy

±0.1mm to ±0.3mm

Tolerance on critical part dimensions to ensure precise fit and functionality.

Surface Finish

Ra 0.8 to Ra 1.6

Surface roughness for improved quality, assembly compatibility, and aesthetic finish.

Wall Thickness Uniformity

±0.05mm to ±0.1mm

Ensures consistent wall thickness across complex geometries to prevent weak spots.

Flatness

≤ 0.1mm

Ensures minimal deviation in flatness for proper assembly and functional alignment.

Angular Deviation

±0.05° to ±0.5°

Tolerance on angular features to ensure precise geometry and correct part mating.

Hole Diameter

±0.05mm to ±0.1mm

Precise tolerance for holes to accommodate inserts, fasteners, or other components.

Concentricity

≤ 0.05mm

Ensures that holes or circular features are centered within specified tolerances.

Cylindrical Perpendicularity

±0.1mm to ±0.3mm

Tolerance for perpendicularity in cylindrical features to ensure proper assembly.

Profile of a Surface

±0.2mm to ±0.5mm

Tolerance for the contour of a surface to ensure uniformity and fit in mating parts.

Position Tolerance

±0.1mm to ±0.3mm

Tolerance on the position of features (holes, slots) relative to other features.

Length/Width/Height

±0.2mm to ±0.5mm

Tolerance for overall part dimensions, ensuring parts fit within assembly constraints.

Straightness

±0.1mm to ±0.2mm

Tolerance for linear features to maintain accuracy in length and straight alignment.

Roundness

±0.05mm to ±0.1mm

Ensures circular features maintain roundness for proper sealing or assembly.

Taper

±0.2° to ±1.0°

Tolerance for tapered features to ensure proper fit and function in assemblies.

Thickness Variation

±0.05mm to ±0.1mm

Ensures uniform material thickness across the part, preventing weak or stressed areas.

Surface Distortion

≤ 0.2mm

Ensures minimal distortion after cooling, critical for maintaining part integrity.

Radii and Fillet

±0.1mm to ±0.2mm

Tolerance on radii and fillet features to ensure smooth transitions and prevent stress concentrations.

Quality Testing Standards for Shell Molding Services

Core Integrity

X-ray Inspection or CT Scanning

Detects defects such as voids, cracks, or inconsistencies within the core structure.

Mold Hardness

Rockwell or Vickers Hardness Testing

Measures the hardness of the mold material to assess wear resistance and durability.

Thermal Conductivity

Thermal Conductivity Testing

Measures the material's ability to conduct heat, ensuring proper cooling and mold performance.

Porosity

Helium Leak Testing or X-ray Inspection

Identifies porosity in the castings to ensure structural integrity and performance.

Casting Strength

Tensile Testing or Bend Testing

Assesses the mechanical strength of the casting under tension or bending forces.

Creep Resistance

Creep Testing

Measures the material’s ability to resist deformation under high temperature and stress over time.

Dimensional Stability

Thermal Cycling or Stress Testing

Evaluates the material's dimensional stability under varying temperature conditions.

Ductility

Impact Testing or Elongation Testing

Assesses the material's ability to deform under stress without fracturing, important for automotive or aerospace applications.

Metallurgical Properties

Metallographic Analysis

Evaluates grain structure, inclusions, and phase distribution within the material.

Fatigue Resistance

Fatigue Testing

Measures the material’s ability to withstand repeated cycles of stress without failure.

Microstructure Quality

Scanning Electron Microscopy (SEM)

Provides detailed analysis of the microstructure to identify any microscopic defects or irregularities.

Weldability

Weldability Testing

Assesses the ability of the material to be welded without compromising structural integrity.

Chemical Composition

Spectroscopy or XRF (X-ray Fluorescence)

Analyzes the chemical composition of the material to ensure it meets alloy specifications.

Hardness Distribution

Microhardness Testing /

Measures hardness across the material at micro levels, detecting inconsistencies in hardness distribution.

Residual Stress

X-ray Diffraction or Strain Gauge

Detects residual stresses that could affect the performance and longevity of the part.

Inspection Techniques in Shell Molding

Visual Inspection

Parameters - Surface finish, cracks, porosity, defects

Value/Range - 0.1 - 2 mm defect detection

Aerospace (turbine blades, engine components), Automotive (brake components), Industrial (machinery parts)

Ultrasonic Testing

Parameters - Thickness, cracks, internal defects

Frequency range: 1 - 10 MHz

Resolution: 0.01 mm

Aerospace (critical structural parts), Automotive (engine blocks), Industrial (heavy-duty parts)

X-ray Inspection

Parameters - Internal voids, porosity, inclusions

Resolution: 0.5 - 2 mm

Penetration: up to 50 mm

Aerospace (turbine parts), Automotive (cylinder heads), Industrial (casting defects)

Magnetic Particle Inspection (MPI)

Parameters - Surface and near-surface cracks

Sensitivity: 0.1 - 1 mm, Type: Fluorescent, Dry

Automotive (gearboxes, suspension components), Aerospace (engine parts), Industrial (critical machine parts)

Dye Penetrant Testing (DPT)

Parameters - Surface cracks, porosity

Penetration depth: 0.1 - 1 mm

Aerospace (engine components), Automotive (brake systems), Industrial (precision castings)

Computed Tomography (CT)

Parameters - 3D structural analysis, internal porosity

Resolution: 0.1 - 1 mm

Aerospace (turbine blades), Automotive (complex engine components), Industrial (high-precision molds)

Eddy Current Testing (ECT)

Parameters - Surface cracks, material composition

Frequency: 100 kHz - 10 MHz

Depth: 0.2 - 2 mm

Aerospace (critical parts), Automotive (brake pads, engine components), Industrial (conductivity testing)

Tensile Testing

Parameters - Material strength, elongation, yield strength

Force: 10 N - 500 kN

Elongation: up to 10%

Aerospace (metallic components), Automotive (engine components), Industrial (high-strength parts)

Hardness Testing

Parameters - Material hardness (Brinell, Rockwell, Vickers)

Hardness value: 40 - 60 HRC

Aerospace (turbine blades), Automotive (gearboxes), Industrial (machinery parts)

Dimensional Measurement

Parameters - Tolerance, shape accuracy

Tolerance: ±0.01 - ±0.5 mm

Aerospace (high-precision components), Automotive (engine blocks), Industrial (complex toolings)

Industry applications of Shell Molding

Aerospace

Manufacturing complex, high-performance parts for engines and structures

Turbine blades, heat shields, combustion chambers, structural supports

Automotive

Precision casting for lightweight, durable automotive components

Engine blocks, cylinder heads, suspension parts, gearbox housings

Medical

Production of highly precise, biocompatible, and sterile medical parts

Surgical instruments, joint replacements, bone screws, dental implants

Industrial

Manufacturing high-strength, wear-resistant components for machinery

Pumps, valves, gearboxes, bearing housings, turbine components

Defense

Precision and strength-critical castings for defense equipment

Military vehicle components, bomb casings, missile housings, radar systems

Energy

Casting for components used in high-stress, high-temperature environments

Gas turbines, pressure vessels, valves, nuclear reactor parts

Electronics

Manufacturing of small, intricate components for circuit assembly

Connectors, capacitors, housing for sensors, enclosures for microelectronics

Marine

High-strength, corrosion-resistant castings for marine equipment

Propellers, ship engine components, sea valves, hull attachments

Construction

Durable and heavy-duty castings for machinery and structural applications

Concrete molds, excavation equipment parts, structural steel brackets, heavy machinery frames

Oil & Gas

Casting for high-durability parts for offshore and drilling applications

Valve bodies, drilling equipment, pump housings, flanges, pressure housings

Food Processing

High-precision components for machinery in food production

Mixing blades, conveyor system parts, valves, strainers, pumps

Telecommunications

Precision components for communication devices and systems

Antenna components, connector housings, mounting brackets, sensor casings

Transforming Engine Component Manufacturing with Shell Molding

Engine component manufacturers often struggle to achieve the precision and durability required for critical parts. Shell molding provides a solution by delivering high accuracy and superior surface finishes for complex engine components. This process ensures that intricate geometries, tight tolerances, and high-strength materials are consistently maintained, reducing the need for additional machining. Shell molding’s ability to work with high-temperature alloys like Inconel and titanium makes it ideal for demanding engine applications, resulting in parts that can withstand extreme conditions while maintaining structural integrity and performance.

Industries We Serve

What You Gain with Us

We make your profitability and operations easier with practical approach.

Consistent Surface Quality Across Large Production Runs

Achieving consistent, defect-free surface finishes is essential for precision components. Frigate’s shell molding process delivers smooth surfaces with minimal need for additional machining. The careful control over mold design, material pouring, and cooling ensures uniformity across large production runs. This reduces the likelihood of surface defects such as porosity or roughness, ensuring parts meet both aesthetic and functional requirements. The result is high-quality, consistent parts with superior surface finishes, ideal for industries demanding tight tolerances and precision.

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What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does shell molding maintain structural integrity in high-performance components?

Shell molding ensures optimal material flow during molding, preserving microstructural integrity. This minimizes defects such as porosity, ensuring the mechanical properties of high-performance components remain intact.

What role does shell molding play in achieving high-density alloys for critical applications?

The precision of shell molding allows for uniform density distribution in high-density alloys. This ensures consistent material properties, which are critical for aerospace, defense, and other high-stress applications.

How does shell molding handle alloy-specific challenges like oxidation or carbide formation?

Shell molding minimizes exposure to air during the mold creation, reducing oxidation and carbide formation. This is particularly beneficial when working with high-temperature alloys sensitive to environmental reactions.

How does shell molding's precision improve part consistency across multiple production batches?

The high level of control over the mold material and process parameters in shell molding results in consistent part geometry and properties, even in large production runs with complex, critical features.

How does shell molding contribute to improving fatigue resistance in metal parts?

By reducing defects such as voids and inclusions, shell molding produces parts with superior internal structure and mechanical properties, significantly enhancing fatigue resistance for components under cyclic loading.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Shell Molding Services

Our Clients

Advantages of Shell Molding Services

Reduced Casting Defects

Efficient Production

Dimensional Consistency

Minimal Post-Processing

Custom Shell Molding Services for Precision and Durability

Get Your Quote Now

Our Shell Molding Process

Post-Processing Services in Shell Molding

Methoding in Shell Molding

Shell Molding Materials

Precision in Handling High-Temperature Alloys for Reliable Performance

Compliance for Shell Molding Services

Tonnage in Shell Molding

Dimensions in Shell Molding

Tolerance for Shell Molding Services

Quality Testing Standards for Shell Molding Services

Inspection Techniques in Shell Molding

Industry applications of Shell Molding

Transforming Engine Component Manufacturing with Shell Molding

Industries We Serve

What You Gain with Us

↓ 7-8%

↓ 2-3%

3X

↑ 25%

↓ 50%

↑ 30%

Consistent Surface Quality Across Large Production Runs

Check Out Our Blogs

What Our Customers Say about Frigate

21%

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Global Sales Office

Registered Office

Operations Office

GENERAL ENQUIRIES

Capabilities

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