Sand Casting for a Wide Range of Applications

We’re pleased to offer extensive sand-casting capabilities through our parent company, Sigma Electric Manufacturing Corp.

Sand casting uses relatively low-cost molds, thanks to sand’s inherent compactability, refractory nature and recyclability. Since it requires a relatively low investment, sand casting allows for quick tooling development and part changes at a reasonable cost, making it ideal for working through the evolutions of a part.

Green Sand Casting

The process is often called “green sand casting” because of the moisture content of the molding sand, which is generally made up of silica sand (both new and reclaimed), various bonding clays, carbonaceous materials and water. To create a mold, the prepared sand is compacted around a pattern that has the shape of the desired casting.

Markets & Products

We use sand casting to produce parts for a wide range of industries, such as:

  • Electrical
  • Lighting
  • Power transmission and distribution
  • Industrial appliances

The size of end products can range from an ounce or less to more than 40 pounds. Examples include small parts like gears, pulleys, connecting rods and propellers as well as larger components such as pump components, manifolds, cylinder heads and transmission cases.

The process is well-suited to applications that require complex geometries.

Operations’ Heart

Sigma’s facilities at its Jaipur, India, location are the heart of our sand casting operations. The location features five plants, each with its own characteristics.

Plant J0 is a 48,577-square-foot facility with an annual capacity of 2,103 tons. It is dedicated to ferrous casting with materials like malleable cast iron‚ grey iron and ductile iron.

With 27,286 square feet, Plant J1 is a non-ferrous foundry, processing copper, aluminum and bronze. Its annual capacity is 873 tons.

Plant J2 also is a non-ferrous facility, processing copper alloys‚ aluminum and zinc. It has 36,995 square feet and an annual capacity of 1,283 tons.

A ferrous foundry, Plant J3 has 98,059 square feet and 3,981 tons of annual capacity. It handles malleable iron‚ grey iron and ductile iron. Plant J3 features Industry 4.0 technology, as well as high-end robotic automation for secondary machining operations.

Plant J4 is a state-of-the-art fully automatic foundry, featuring auto-pouring of molten grey iron and ductile iron. It also employs high-end robotic automation for secondary machining operations. The 135,797-square-foot facility has 3,836 tons of annual capacity.

Extended Capabilities

Beyond sand casting and secondary machining operations, we also offer:

  • Prototyping
  • Production tooling
  • Automated surface treating
  • UL testing
  • Assembly and packing

The Jaipur facilities also have several quality certifications: ISO 9001:2015, ISO 14001:2015 and 45001:2018 Integrated Management System.

Contact us today to learn if sand casting is right for your application.

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