Durable Steel Components with Airset Casting
Eagle Alloy utilizes airset casting, also known as no-bake casting, to produce durable, complex steel castings that meet stringent dimensional and performance requirements. This process supports a wide range of part sizes and geometries while maintaining consistent quality, making it ideal for lower-volume runs.
What Is Airset Casting?
Airset casting relies on chemically bonded sand that cures at room temperature. Unlike shell molding, it doesn’t require heat to form the mold. The ability to use finer sand grains results in stronger molds and fewer surface defects. This process excels at producing structurally sound parts with good cosmetic appearance and dimensional reliability. It is especially helpful for applications where shell molding may not be cost-effective.
At Eagle Alloy, airset casting allows us to:
- Pour large and intricate parts without sacrificing strength
- Produce short- and medium-run quantities with flexibility in scheduling
Eagle Alloy's Airset Capabilities
Airset molding is supported by in-house mixing, molding, finishing, and inspection systems designed specifically for steel castings. Our Palmer auger mixer provides a consistent flow of sand mix, while our Kloster rollover helps us quickly produce molds up to several feet in size. We regularly handle both prototype castings and repeat production runs for critical parts.
We work with:
- Carbon steels
- Stainless steels
- Specialty and custom alloys
Every project undergoes rigorous in-process and final inspection to meet your dimensional and material specifications.
Download a detailed list of the material we cast and alloys poured here.
Shell Mold Casting Compared to Other Methods
| CASTING METHOD | TOOLING COSTS | LABOR COSTS | TYPICAL TOLERANCES | SURFACE FINISH | TYPICAL VOLUME |
|---|---|---|---|---|---|
| Airset Casting | Low | High | ±0.063″ | Fair | Low |
| Shell Mold Casting | Medium | Medium | ±0.030″ | Good | Medium |
| Investment Casting | Medium | High | ±0.005″ | Very Good | Low to High |
| Greensand Casting | Low | Medium | ±0.030″ | Fair | Low to Medium |
When to Choose Airset Casting
Airset casting is an excellent option when your project requires:
- Durable steel castings with minimal surface defects
- Complex internal geometries without the cost of shell tooling
- Quick-turn prototypes or flexible low- to medium-volume production
- Freedom to design without strict heat limitations on tooling
It also serves as a bridge process for customers transitioning from fabrication to casting or switching suppliers who do not provide access to tooling or blueprints.
Get Started with Airset Casting
Eagle Alloy brings decades of experience, advanced facilities, and a strong track record of on-time delivery to every project. Whether you’re producing a prototype or preparing for ongoing production, our airset casting capabilities are built to support your goals.
Contact Our Team to learn more about how Eagle Alloy can deliver reliable airset steel castings for your application.