Transferred Aluminum Casting Tooling
Move an Existing Casting Program Without Automatically Starting Over
Changing aluminum foundries does not always mean replacing your patterns, match plates and core boxes. Cast Metals Technology works with manufacturers that need to transfer established aluminum sand casting programs from another supplier and, in most cases, can accommodate transferred casting tooling after it has been evaluated for condition and equipment compatibility.
CMT can inspect, recondition and rig existing patterns and core boxes, helping customers develop a practical path from the current supplier to production at our Ohio and Indiana foundries.
Why Manufacturers Transfer Aluminum Casting Tooling
An established casting program may need a new home for reasons that have nothing to do with the part design. Common triggers include:
When usable tooling already exists, the first question should be whether it can be transferred and adapted – not whether the customer must immediately purchase an entirely new tool.
Foundry closure or ownership change
Capacity constraints
Delivery or lead-time problems
Recurring quality issues
Need for a second source
Supplier consolidation
Need for domestic production
Program growth beyond the current supplier’s capacity
Desire to combine casting and CNC machining with one supplier
What Casting Tooling Can Be Evaluated?
Depending on the molding process and program, transferred tooling may include:
- Match plates
- Patterns
- Core boxes
- Loose pieces and inserts
- Gating and runner components
- Mold boxes or related pattern equipment
- Machining fixtures and inspection fixtures
CMT’s tooling capabilities include reconditioning transferred patterns and core boxes, rigging new and existing tooling, tooling design and engineering, and CNC-cut new pattern and core-box tooling when replacement or modification is required.
How the Tooling Transfer Process Works
- Project review – CMT reviews the casting drawing, 3D model, alloy, annual volume, current process, machining requirements and available tooling information.
- Tooling inspection – Patterns, match plates and core boxes are evaluated for condition, wear, dimensions, gating and compatibility with CMT equipment.
- Process and equipment fit – The team determines which CMT molding process and equipment are appropriate for the part and existing tool.
- Reconditioning or modification – When practical, transferred tooling can be repaired, reconditioned, re-rigged or modified rather than replaced.
- Engineering validation – Gating, risering, shrink allowance, core placement and machining stock can be reviewed; casting simulation may be used where appropriate.
- Sampling and dimensional verification – Initial castings are produced and inspected before normal production requirements are established.
- Production transition – Once the casting and process are approved, the program can move into the appropriate CMT production system.
Compatibility With Automated Molding Equipment
CMT operates both manual and automated aluminum sand molding systems. Its automated molding equipment is capable of running tooling made for Hunter, Roberts Sinto and DISA Match molding machines, which can make CMT particularly useful when an established program needs to be transferred from another aluminum foundry.
Compatibility still needs to be verified for each individual tool. Flask size, match-plate dimensions, gating, pattern layout, core requirements and tool condition can all affect the transfer plan.
Have Tooling to Transfer?
Send CMT photos or drawings of your existing patterns, match plates and core boxes and we will review them.
What If the Existing Tooling Is Worn or Damaged?
Transferred tooling does not have to be perfect to be worth evaluating. Depending on its condition, CMT may be able to recondition patterns and core boxes, repair components, modify rigging or replace only the portions that are no longer suitable for production.
If a tool cannot be economically adapted, CMT can also support the design and manufacture of new pattern and core-box tooling. The objective is to preserve usable customer assets where practical while establishing a reliable production process.
What If Core Boxes Are Missing?
Missing core tooling is a common complication in older or transferred casting programs. CMT can evaluate whether a replacement core box is required or whether 3D-printed sand cores may provide another option for selected applications.
If a replacement core box is needed, CMT can take care of quoting it.
This can be especially useful for legacy components, low-volume requirements, complex internal geometry or programs where recreating several conventional core boxes would add significant cost and lead time.
Transfer the Casting and the Machining
Re-sourcing can also be an opportunity to simplify the supply chain. CMT provides precision CNC machining in addition to aluminum casting, including turning, live-tool lathes, 4-axis and 5-axis milling, CMM inspection and in-house fixture design.
For a machined casting, transferring both operations to one supplier can reduce freight, work-in-process, handoffs and ambiguity over responsibility for the finished component.
What Should You Send CMT?
To evaluate a transferred casting program efficiently, provide as much of the following as possible:
Current casting drawing and revision
3D CAD model
Machining drawing
Alloy and heat-treatment requirements
Estimated annual usage
Current casting weight
Photos and dimensions of existing patterns/match plates
Core-box information
Current quality requirements or PPAP documentation
Known dimensional, quality or delivery issues
Current production tooling location and ownership information
A Practical Second Source for Existing Aluminum Castings
CMT’s combination of low- and high-volume sand casting, manual and automated molding, tooling support, core making, in-house heat treatment, engineering, solidification analysis and CNC machining gives manufacturers multiple options when an established casting program needs to move.
Instead of assuming that existing tooling is unusable, let our team evaluate the assets and determine the most practical and cost effective path to production.
Learn more about why manufacturers choose CMT as a Midwest aluminum sand casting foundry.
Frequently Asked Questions
Can CMT use tooling from another aluminum foundry?
In most cases, CMT can accommodate transferred casting tooling, but each pattern, match plate and core box should be inspected for condition and compatibility with the intended molding equipment.
Does transferred tooling have to be rebuilt?
Not necessarily. CMT can recondition transferred patterns and core boxes and rig existing tooling. The amount of work depends on tool condition, dimensions, gating and molding-equipment compatibility.
Can CMT run tooling made for automated molding machines?
CMT’s automated molding machines can run tooling made for Hunter, Roberts Sinto and DISA Match molding machines, subject to review of the specific tool and application.
What if the original core boxes are missing?
CMT can evaluate replacement tooling and, for selected applications, whether 3D-printed sand cores provide a practical alternative.
Need to Move an Aluminum Casting Program?
Send CMT your part information and photos or drawings of the existing tooling. We can review the program, discuss equipment compatibility and identify what would be required to transfer the casting to CMT.