Our Process

Step One

3D Tool Modeling

All tooling is designed and produced utilizing our experienced team of designers. Tooling models have ranged from cast iron to plastic process tooling models. We can take the customer supplied model, check and repair draft, machine stock and parting lines. From there, we can set up core prints, build core boxes and pattern models as well as create complete follow board surfaces. Appropriate clearances are ensured by our designers for core to cope and drag setting.

3D Tool Modeling Software

Powermill
CATIA
Solidworks
PTC CREO
CATIA
Powershape

3D Tool Modeling Gallery

Step Two

CNC Cut Tooling

Our 40,000 sq-ft home facility holds 10 horizontal and vertical machining centers. Travel sizes range from 16” up to 158” giving us the flexibility to handle small and large jobs. We are widely versed in machining both plastics and metals and are able to accommodate all commercially available materials. In addition, we also offer full machining services on patterns and prototype castings.

CNC Cut Tooling Gallery

Step Three

Sand Molding

No-Bake Sand Molding & Core Making

American Pattern and CNC Works no -bake molding shop offers the most up to date technology and resin systems running every day. We calibrate our mixers every week to ensure proper sand to chemical ratios to produce the proper tensile mold strengths. Our shop offers three no-bake molding lines along with a single core blowing station. We also have off-line core making stations.

We can pour castings that range from 1 lb. to 2,000 lbs. and have an in-house chip and grind room to ensure quality and speed.
We have capabilities to produce hand packed air set sand molds and air set cores and core assemblies.
The size of the sand grain used is GFN 55. We utilize a three-part phenolic urethane chemical process for sand set up.
Coating/wash secondary process – we utilize both water base and alcohol base dip and spray coating/wash.
We also have access to 3D sand printing for molds and cores where it’s economically feasible versus standard sand and core making.

Sand Molding and Coremaking Equipment

1 – Tinker Omega TOM 550 No-Bake mixer which is capable of 1,100lbs of sand a minute
2 – Tinker Omega TOM 350 No-Bake mixer which is capable of 550lbs of sand a minute
1 – Tinker Omega No-Bake core machine Blow it 25
1 – Quiptec Mold Manipulator capable of manipulating a 4,000lb mold with dimension of 85X70
4 – Chip and grind booths

Prototype casting Quality Reports

Depending on customers requirements for quality reports we will outsource to our appropriate suppliers for most all reports. Upon request for quote, we can provide the following:

Metal certification identifying the cast metal composition and mechanical properties.
Raw casting layout using 3D scanning or conventional CMM/balloon drawing reports.
Soundness/Radiography reports-(X-ray) for ductile iron castings.
CMM Machined casting reports.

We can also supply Level 4 PPAP reports upon request containing the Part Submission Warrant, Soundness Report, Layout report-raw and/or machined and Metal Certification report.

Sand Molding Gallery

Step Four

The Pour

American Pattern and CNC Works Inc. produces castings in gray iron, ductile iron, Hi-Sil Moly, steel and aluminum using no-bake molds and 3D printing.