As the size increases, the Hydrostatic Pressure on the mold increases. The pattern must be strong enough to not deform under the weight of tons of sand. Additionally, cooling a 3-ton metal casting requires a very specific Riser and Gating design integrated into the pattern to prevent internal cracks.

We use a Multi-Piece Core Box Assembly. The core is made separately and placed inside the mold. Since it’s a "Large Bore" valve, we provide reinforced core prints that prevent the core from shifting or "floating" when the heavy molten metal is poured.

While wood is good, Epoxy Resin is superior for large-scale patterns because it does not expand or contract with humidity. This ensures that the 36-inch dimension stays accurate to the millimeter, even if the pattern is stored in a damp foundry for years.

Yes. We use Interchangeable End-Cap Inserts. You can swap the flange section of the pattern to cast either a flanged valve or a butt-weld end valve using the same main body pattern, saving you significant tooling costs.

For a 36-inch casting, the metal can shrink by nearly an inch as it cools. We use advanced Foundry Simulation Software to apply a precise "Shrinkage Scale" so the final cooled casting matches the exact design specifications.