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NO-BAKE / AIR SET MOLDING.

From One Pound to Thousands.

Flexible no-bake molding for high-volume production and low-volume specialty builds — on two dedicated lines.

Excal’s two air-set/no-bake molding lines cover the full spectrum of casting programs: one line optimized for high-volume production runs, the other configured for low-volume specialty builds and prototyping. Both are capable of castings from one pound to thousands of pounds, giving customers a single source regardless of program size.

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Why No-Bake Molding

The Right Process for Precision and Flexibility

No-bake molding uses chemically bonded sand that cures at room temperature — enabling tighter tolerances, better surface finish, and greater dimensional consistency than green sand for many applications.

High-Volume Line

Dedicated to steady production programs — optimized for throughput, repeatability, and consistent dimensional quality across long runs.

Specialty & Prototype Line

Configured for low-volume specialty castings and first-article prototypes — where flexibility and quick changeover matter more than raw throughput.

Full Weight Range

Both lines handle castings from one pound to thousands of pounds — covering the full range of Excal’s brass, bronze and stainless steel production capabilities. In many cases, the no-bake process allows use of existing tooling in good repair with minimal to no changes.

Our Process — No-Bake Molding

From Sand Mix to Finished Casting

1

Sand Preparation


Sand is mixed with chemical binders at controlled ratios to achieve the required bond strength and cure time for your alloy and part geometry.

2

Mold Construction

Sand is packed around the pattern and allowed to cure — producing a rigid mold with tighter dimensional accuracy than green sand.

3

Core Setting & Assembly

Cores are set and the mold assembled and inspected before the pour — ensuring correct geometry and fit.

4

Pouring, Cooling & Shakeout

Molten metal is poured, the casting cooled, and the mold broken down for cleaning and further processing.

FAQ — No-Bake / Air Set Molding

Your Questions, Our Answers

No-bake is often preferred for larger castings, complex geometries, or applications requiring tighter tolerances and better surface finish than green sand can consistently deliver. Our team can advise on the right process for your part.

Yes. Our specialty/prototype no-bake line is specifically set up for first-article and low-volume work — so you can validate your casting before scaling to production.

Both no-bake lines handle castings from one pound to thousands of pounds, within our overall brass and bronze weight range of 1 to 2,000 lbs.

Our no-bake lines support the full range of brass and bronze alloys we pour, as well as select stainless steel grades. Contact us with your alloy specification and we’ll confirm suitability.

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