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Resin Shell Molding
Shell molding uses sand specially coated with thermosetting phenolic resin for a smooth, hard mold surface. The process is performed on a high production machine which bakes the pattern to approximately 500 degrees, then coats the pattern with the resin-coated sand.
Once the resin hardens to the desired thickness, the mold is stripped away and cores are added if required. The two halves are glued together in a bonding press to minimize "parting line flash" and improve the final casting tolerances and appearance.
Shell molded castings have the best tolerance and surface finish of all the sand-based molding processes. Also many metal options are available, such as, steel, iron, brass, and aluminum.