Casting Capabilities

Industry leading Sand Casting

Bernier Cast Metals, Inc. has been producing sand castings since 1945, and over the past 70 years we have continued to perfect our talent. As a fourth-generation family owned and operated business, we have used our knowledge to pass down the best practices and techniques as well as adopting the latest advancements in casting processes. Specializing in green sand molding, air-set molding, and lost foam casting, we have succeeded in expanding our facilities, technology, equipment and services.

Capabilities

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Air-Set (No Bake)

Dry sand is combined with a liquid resin and hardener. The resulting mixture is then compacted around a pattern and left to set. When the mold halves are pulled apart, the pattern removed, and the mold is closed, molten metal is poured into the mold cavity, creating a casting. The air-set (no bake) process can handle larger and more complex castings than with the green sand molding process.

Equipment:

  • 1 – 300-500 Castec Articulated Continuous Sand Mixer
  • 1 – 50-150 Castec Continuous Sand Mixer
  • 1 – Castec Vibratory Compaction Table
  • 1 – Continuous Tube Sand Heater
  • Flask Sizes: 8″x12″ up to 70″x112″
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Green Sand

Granular refractory mineral is coated with mostly bentonite clay and water, and then compacted (molded) around a pattern. The molten metal is then poured into the mold and allowed to cool, creating a casting. Once the mold has been shaken out, the resulting casting is a strong, durable product. The green sand molding process is used to make simple-shaped castings. The benefits are in lower-cost tooling, faster turnaround, and castings usually less costly than with other molding methods.

Equipment:

  • Jolt and Squeeze Department with Flask Sizes between 10″x16″ up to 14″x20″
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Lost Foam

Dry sand is compacted around a pattern made of expandable polystyrene (EPS) coated with a refractory wash. Molten metal is poured into the mold and replaces the EPS, creating a casting. The lost foam casting (EPC) process offers relatively low-cost tooling for ultra-low quantity (1-3 piece) casting runs and is ideal for prototyping and research and development.

Equipment:

  • 1 – 300-500 Castec Articulated Continuous Sand Mixer
  • 1 – 50-150 Castec Continuous Sand Mixer
  • 1 – Castec Vibratory Compaction Table
  • 1 – Continuous Tube Sand Heater
  • Flask Sizes: 8″x12″ up to 70″x112″
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Wood or plastic patterns directly from customer drawings

If you provide us with a drawing or 3-D solid model, we can produce a wooden or plastic three-dimensional pattern to be used to create a mold.

Patterns:

  • Loose Wood Patterns
  • Matchboards and Matchplates
  • Cope and Drag Boxes
  • SLA Rapid Prototypes direct from CAD Models

Specifications

Quality Standard ISO 9001:2015
Molding Methods Air Set (No Bake)
Green Sand
Materials Aluminum
Brass
Bronze
Copper
Zinc
Gray Iron
Ductile Iron
Carbon Steel
Low Alloy Steel
Stainless Steel
Manganese Steel
Nickel Alloys
Production Volume 1 piece

Prototype

Low Volume

Semi-Production

Typical Lead Time 4 Weeks, Quoted on Job by Job Basis
Casting Weight Ounces to 1000 lbs
Casting Size Length: Up to 108″
Width: Up to 49″
Depth: Up to 40″