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.Â
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.Â
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Our Shell Molding Process
High-quality metal alloys are chosen based on the part's required strength, durability, and performance specifications.
The selected material is heated to a specific temperature, making it more malleable and easier to shape during the forging process.Â
The heated material is pre-formed into a rough shape using controlled pressure, closely matching the final part's dimensions.Â
The pre-formed material is then subjected to high pressure in a die, which shapes it to near-net dimensions, reducing material waste.Â
The forged part is slowly cooled to ensure uniform material properties and to prevent distortion or cracking.Â
To achieve the final shape, minimal machining or surface treatment is required, ensuring tight tolerances and high-quality surface finishes.Â
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.Â
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.Â
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.Â
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.
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.Â
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.Â
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.Â
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.Â
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.Â
Quality management systems for consistent product quality.Â
Automotive quality management standards.Â
Standard specification for zinc and zinc alloys used in molding.Â
Environmental management system for reducing waste and energy consumption.Â
Occupational health and safety standards ensuring a safe working environment.Â
Aerospace quality certification for materials and processes.Â
Adherence to European Union regulations on chemical substances used in molding.Â
Tolerance for Shell Molding Services
Tolerance on critical part dimensions to ensure precise fit and functionality.Â
Surface roughness for improved quality, assembly compatibility, and aesthetic finish.Â
Ensures consistent wall thickness across complex geometries to prevent weak spots.Â
Ensures minimal deviation in flatness for proper assembly and functional alignment.Â
Tolerance on angular features to ensure precise geometry and correct part mating.Â
Precise tolerance for holes to accommodate inserts, fasteners, or other components.Â
Ensures that holes or circular features are centered within specified tolerances.Â
Tolerance for perpendicularity in cylindrical features to ensure proper assembly.Â
Tolerance for the contour of a surface to ensure uniformity and fit in mating parts.Â
Tolerance on the position of features (holes, slots) relative to other features.Â
Tolerance for overall part dimensions, ensuring parts fit within assembly constraints.Â
Tolerance for linear features to maintain accuracy in length and straight alignment.Â
Ensures circular features maintain roundness for proper sealing or assembly.Â
Tolerance for tapered features to ensure proper fit and function in assemblies.Â
Ensures uniform material thickness across the part, preventing weak or stressed areas.Â
Ensures minimal distortion after cooling, critical for maintaining part integrity.Â
Tolerance on radii and fillet features to ensure smooth transitions and prevent stress concentrations.Â
Quality Testing Standards for Shell Molding Services
Detects defects such as voids, cracks, or inconsistencies within the core structure.Â
Measures the hardness of the mold material to assess wear resistance and durability.Â
Measures the material's ability to conduct heat, ensuring proper cooling and mold performance.Â
Identifies porosity in the castings to ensure structural integrity and performance.Â
Assesses the mechanical strength of the casting under tension or bending forces.Â
Measures the materialâs ability to resist deformation under high temperature and stress over time.Â
Evaluates the material's dimensional stability under varying temperature conditions.Â
Assesses the material's ability to deform under stress without fracturing, important for automotive or aerospace applications.Â
Evaluates grain structure, inclusions, and phase distribution within the material.Â
Measures the materialâs ability to withstand repeated cycles of stress without failure.Â
Provides detailed analysis of the microstructure to identify any microscopic defects or irregularities.Â
Assesses the ability of the material to be welded without compromising structural integrity.Â
Analyzes the chemical composition of the material to ensure it meets alloy specifications.Â
Measures hardness across the material at micro levels, detecting inconsistencies in hardness distribution.Â
Detects residual stresses that could affect the performance and longevity of the part.Â
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 moldingâs 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.Â
Industries We Serve
What You Get
â 7-8%
OPS COST
â 2-3%
COGM
3X
Aggregation
â 25%
Machinery Utilisation
â 50%
Expedition
â 30%
Frigater Revenue
Consistent Surface Quality Across Large Production Runs
Achieving consistent, defect-free surface finishes is essential for precision components. Frigateâs 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.Â
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
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.Â
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.Â
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.Â
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.Â
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.Â
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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. ă ¤
