At Tonkawa Foundry, our seamless production process is a testament to our commitment to delivering exceptional castings to our valued customers. From the meticulous art of molding, where we employ various techniques including stack molding, no-bake, cold box, and phenolic urethane cold box molding, to the precise melting process featuring state-of-the-art equipment and premium materials like American pig iron and copper, we ensure the utmost quality in every casting. Our dedication extends to sustainable practices, as seen in our Shakeout and Sand Reclamation process, where we reclaim and reuse sand efficiently while maintaining environmental responsibility. Finally, our unwavering focus on perfection culminates in the preparation and inspection phase, where castings undergo rigorous assessments, stand and hand grinding, and shot blasting to guarantee they meet our stringent standards.
At Tonkawa Foundry, we blend craftsmanship, precision, and sustainability to deliver superior castings tailored to your specific needs.
At Tonkawa Foundry, we blend craftsmanship, precision, and sustainability to deliver superior castings tailored to your specific needs.
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Our Processes
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•MOLDING
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Molding PROCESS
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At Tonkawa Foundry, our molding process is a cornerstone of our precision casting capabilities. With complete tooling capabilities available through local pattern shops, we offer versatile molding solutions to meet your specific requirements. Our stack molding capabilities range from 13.5" x 15" up to 16" x 24" with mold thicknesses from 1.5" to 3". We excel in no-bake, cold box, and phenolic urethane cold box molding techniques to achieve superior dimensional accuracy. Additionally, our investment in mold handling equipment ensures efficient and consistent production. With a commitment to delivering top-quality castings, our molding expertise stands as a testament to our dedication to craftsmanship.
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MELTING PROCESS
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Tonkawa Foundry upholds uncompromising standards in the melting process to ensure the integrity of our castings. We exclusively use premium materials such as American pig iron, #1 copper, new nickel, chrome, and more, safeguarding the quality of our products. Our state-of-the-art facilities are equipped with 1200 kW Inductotherm Power Units, along with two 2000-pound furnaces, all controlled with precision through thermocouple temperature monitoring. The integration of our furnace and pouring station, coupled with computerized scales managing accurate charging, guarantees consistency and reliability throughout the melting process. Our commitment to using top-notch materials and advanced equipment sets us apart in delivering castings of unmatched quality.
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Shakeout/Sand Reclamation
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Tonkawa Foundry places a premium on sustainability and efficiency in our operations, as exemplified by our Shakeout and Sand Reclamation process. In 2010, we installed a Sand Reclamation unit to enhance our environmental responsibility and ensure top-notch service to our customers. Our vibratory breakdown of molds in the vibra-drum shakeout unit allows for efficient and thorough separation of castings and sand. We go the extra mile by screening, cooling, and treating sand for re-use, minimizing waste and reducing our ecological footprint. Daily tests conducted by our in-house sand lab ensure that the reclaimed sand meets our stringent quality standards. Our commitment to sustainable practices is reflected in every aspect of our operation.
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Preparation and Inspection
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At Tonkawa Foundry, we leave no room for compromise when it comes to the preparation and inspection of our castings. Our dedicated team meticulously performs full inspections to ensure that each product meets the highest quality standards for our customers. The process begins with initial inspections and cleaning of castings, followed by stand and hand grinding to achieve precise dimensions and surface finishes. Shot blasting adds the final touch, enhancing the appearance and performance of our castings. Through rigorous final inspections, we guarantee that only products of exceptional quality leave our facilities. Our unwavering commitment to precision and excellence is evident in every casting we produce.
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