Internal Geometries. In-House.
Cores Made and Assembled at Ironbound
Many of the castings we produce — valve bodies, pump housings, manifolds, and propeller hubs — require sand cores to form internal passages and geometries that cannot be pulled from a two-piece mold. All cores at Ironbound Castings are made in-house, using no bake furan and phenolic urethane processes matched to the alloy being poured.
Core prints are verified against the pattern before mold close. Multi-piece core assemblies are glued and checked dimensionally in-house. For prototype and first article castings, 3D sand printed cores are available in 5–7 business days from an approved CAD file — no core box required, no pattern modification, no tooling lead time.
In-House Core Making
No bake, shell, and 3D sand printed cores — designed, made, and assembled at Ironbound Castings
Services
Core Making Services
Three core processes available in-house — matched to your alloy, geometry, and production requirements.
No Bake Sand Cores
Furan and phenolic urethane no bake cores are our standard for production castings requiring internal passages. Core mix is adjusted for the alloy being poured — ensuring proper collapsibility and gas permeability without core defects in the casting.
Shell Sand Cores
Shell cores are used for smaller, high-definition internal features where dimensional accuracy is critical. The shell process produces hard, precise cores with excellent surface finish and low gas generation.
3D Sand Printed Cores
Sand cores printed directly from CAD files using binder jet 3D sand printing — no core box required. Ideal for prototype castings, first articles, and one-off complex geometries. Available in 5–7 business days from approved CAD geometry.
Multi-Piece Core Assemblies
Complex internal passages that require multiple individual cores are assembled and glued into a finished core set in-house. Core assemblies are dimensionally checked before mold close to verify passage geometry and core print fit.
Why Ironbound
In-House Core Making Advantages
No Bake & Shell Cores
We produce no bake (furan and phenolic urethane) and shell sand cores for complex internal passages, undercuts, and geometries that cannot be formed by the mold alone. Core mix is controlled to the casting alloy being poured.
Complex Internal Geometries
Cores are used to create internal passages in valve bodies, pump housings, manifolds, and propeller hubs. We design core prints and venting to ensure cores seat correctly and gas purges during pouring.
Core Assembly
Multi-piece core assemblies are assembled and glued in-house. Core sets are checked dimensionally before the mold is closed — ensuring that internal passages are correct before a drop of metal is poured.
3D Sand Printed Cores
For prototype and short-run castings, cores can be 3D sand printed directly from CAD geometry. No core box required — complex internal forms are printed and ready for the mold in 5–7 business days.
Specifications