Molding Process
Pattern Preparation & Sand Moulding
Our moulding process begins with the creation of high-quality patterns that define the exact shape and dimensions of the final casting. These patterns are placed into specialized moulding boxes, where high-grade foundry sand mixed with binding agents is compacted around them to form durable sand moulds. The sand mixture is precisely formulated to ensure strength, permeability, and dimensional accuracy, providing a reliable foundation for every casting we produce
Metal Pouring & Solidification
Once the moulds are prepared, molten metal from our dual 10-ton induction furnaces is carefully poured into the cavities. Our trained operators monitor the pouring temperature and flow rate to prevent defects and ensure complete filling of the mould. The metal then cools and solidifies within the sand mould, forming the desired shape with excellent structural integrity. This stage is critical in achieving consistent casting quality and minimizing internal stress or porosity.
Shakeout & Finishing
After solidification, the moulds are broken apart in a process known as shakeout, revealing the newly formed castings. The castings are then cleaned to remove any remaining sand, flash, or surface residue. Each component undergoes finishing processes such as grinding, trimming, or shot blasting to achieve the required surface smoothness and dimensional precision. Every casting is inspected for quality and accuracy before being approved for delivery to our clients.
Satisfaction Guarantee
At Kethstone Foundry, we are committed to delivering castings that meet the highest standards of precision and reliability. Our Satisfaction Guarantee ensures that every product is manufactured in strict compliance with technical specifications and quality requirements. If any casting does not meet these expectations, we take immediate corrective action — through replacement, rework, or process refinement. We pride ourselves on providing dependable foundry solutions backed by expertise, craftsmanship, and customer satisfaction.