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About Plymouth Foundry
Products and Services
Green Sand Iron
CNC Machining &
3-D Printing &
By Item #
Green Sand Castings
Green Sand Castings
Green Sand Castings
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With over 6 decades of experience in green sand casting, Plymouth Foundry manufactures small components weighing 1 oz as well as complex parts up to 150 lbs in weight. Typical ASTM-grade casting materials that we use in our sand casting process include austenitic ductile iron, ductile iron, and gray iron. Available with tensile strengths from 20,000 psi to 100,000 psi, our high quality casting materials are suited for manufacturing general engineering parts that require high strength and wear resistance as well as pressure containing parts used in low temperature service environments.
Through spectrometer analysis and automatic nodularity testing, Plymouth Foundry inspects the quality of casting materials with ASTM specifications, prior to pouring. With in-house Brinell testing capabilities, we also verify material hardness for specific applications. Using recyclable sand molds, we manufacture custom sand cast parts up to 28" in length, 28" in width, and 14" in height. Mold sand quality is consistently controlled using a Hartley Sand Control system. We produce parts highly cored from shell, and isocure sand as well as parts without core.
Our green sand casting foundry is equipped with an automated sand delivery and mold handling system. The FBO-III Roberts Sinto Flaskless automatic molding system allows us to run castings that fit in a 20" x 24" flask and can be run with a maximum height of 8" in both cope as well as drag. The equipment regulates mold hardness consistency to minimize parting lines and core flashing, which in turn reduces your secondary finishing costs.
To store custom-built patterns, we maintain a separate storage facility built with fire-resistant wall panels and a sprinkler system. Plymouth Foundry’s green sand molding facility also includes Rota-lift molding machines. All melting takes place in two 4,000 lb capacity coreless induction electric furnaces. After cooling, we process the castings in a cleaning room fitted with grinding stations and spinner blast equipment.
Repairs, mounting, gating and rigging of tooling are performed in our pattern shop. We can also work closely with a number of outside tool makers to create or modify patterns and coreboxes to your specifications.
Furnish castings to customers’ specific requirements
Automotive and Machine Components
Compressors & Expanders
Medium Gear Blanks
Municipal and Water Works
Street Lamp Posts
(We can meet unique specifications of customers)
Pressure Equipment Directive (PED) 97/23/EC 7/2, Annex I, Paragraph 4.3
Austenitic Ductile Iron
High Silicon High Moly Ductile Iron
Tensile Strength (Castings)
20,000 psi to 100,000 psi
Green Sand Casting Process
From 1 unit to several thousand units per run
Low Volume to Mid Volume
Short to Medium Runs & Prototypes
Lead Times Available
Quoted on job by job basis
Additional Services Provided
New Pattern Equipment Procurement
Pattern Repair, Mounting, Gating, & Rigging
Inventor (IDW, IPT)
Pro-E or Pro/Engineer (DRW,PRT,XPR)
1 oz to 150
FBO-III Roberts Sinto Automatic Molding Machine (Flask Size: 20" x 24")
Rota-lift (Flask Sizes: 26" x 26" and 30" x 30")
2 - 4,000 lbs Coreless Induction Electric Furnaces
Disco 3100 Isocure
1 - Wheelabrator
1 - Spin Blast
2 - 30" Grinding Stations
4 - Secondary Grinding Stations
Pattern Storage Facility
Concrete building with a sprinkler system & fire walls separating pattern storage building from foundry.
Continuous improvement process that improves customer satisfaction and eliminates waste
Understand the quality expectations of our customers, thereby improving customer satisfaction
Deliver defect-free products to our customers on time
Continually train our employees in quality related matters
Develop quality improvement plans with our key customers and suppliers
Quality Control Capabilities
When we receive your order, a barcoded shop card featuring digital images is created, and all pertinent details are programmed into our Manufacturing Process Control system. As your order progresses through our shop, each department has detailed instructions to ensure that your parts are made to the proper specifications.
This system documents each step in the casting process, allowing us to determine the exact cost for each part and pass the savings on to you.
Our Hartley Sand Control system enables us to regulate the characteristics of the sand used in the molding process.
We utilize advanced technologies to see that you receive what you ordered. Spectrometer analysis and automatic nodularity testing ensure conformance to your specification and traceability by part number, heat code, and ladle. Brinell testing verifies hardness per specifications.
A Melt Analysis module allows us to keep detailed records of the chemical and physical properties of the metal we pour.
Computer tracking of in-house scrap promotes pro-active continuous improvement to meet quality requirements.
A special Corrective Action module in our manufacturing software package gives us the capability of following through on problems to see that they are resolved promptly and efficiently.
Our cutting edge production scheduling program module allows us to deliver both cast and machined parts on-time.
The bar-code order tracking system we use tells us within seconds where your order is in either the casting or machining divisions. This allows us to meet promised delivery dates, and you to schedule your production runs with the assurance that your castings will arrive on time, eliminating idle machines and costly downtime.
Plymouth Foundry Inc. 523 W. Harrison Street, P.O. Box 537, Plymouth, IN 46563 | Tel: 574-936-2106 | Fax: 574-936-5705 |
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