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The Disamatic C3 is a compact, vertical molding machine introduced in India and China during 2016, before its worldwide roll-out late last year.

A New Look for High-Volume Moldmaking

April 24, 2017
The Disamatic C3 offers affordable, consistent green-sand molding available to small and midsized foundries everywhere. Entry-level vertical molding Building on accumulated knowledge Maximum capacity, minimum investment

By the evidence of headlines, it may seem that foundries everywhere have embraced additive manufacturing technology for producing sand molds. The design flexibility and the dimensional accuracy of sand printing are certainly credits to such technical developments, but for some foundries the objective remains production volume. And for those who hold that view, there has been a consistent source of production technology for more than 50 years.

DISA Industries last year began the global introduction of its new high-volume vertical molding system, the Disamatic C3. After several initial installations at foundries in China and India, DISA began making the machines available worldwide for small and midsized foundries seeking an affordable and flexible, entry-level vertical molding process.

Introduced in 1962, the Disamatic process involves a molding machine and conveyor: with compressed-air power, green sand is deposited in a steel chamber, and then squeezed against the opposing patterns placed on either side of the chamber.

After squeezing, one of the chamber plates is opened and the opposing plate pushes the newly formed mold onto the conveyor. Cores may be set into the mold cavity at this point, as the process starts again to produce a subsequent mold. Finished molds are transported by conveyor to a pouring station.

The Disamatic C3 is equipped for manual core-setting, with a speed of 120 mph with manual core-setting in use and up to 150 mph without core-setting.

In addition to its high-volume capability, the chief advantage of Disamatic molding is that it is flaskless, which simplifies the process for the foundry. Also, it reduces sand consumption because mold thickness can be optimized as necessary. And, it’s a process with low labor requirements

All these advantages remain significant for the market targeted by the new design. The Disamatic C3 is a vertical molding system for green-sand casting of various gray and ductile irons, and other metal alloys, for multiple mold sizes, and for either cored and un-cored part designs. According to the developers, it was designed specifically for small and midsized foundries seeking a high return on a modest investment.

DISA reported that the results of the initial installations of the C3 system have been “impressive.” During 2016, more than 15 machines were installed for metalcasting operations in India and China, including the automatic mold conveyor system and an automatic core setter as part of its basic equipment.

“The global rollout of the Disamatic C3 builds on our accumulated knowledge from the Chinese and Indian markets. It is a machine that addresses and fully meets the needs of the small and midsized foundries everywhere, boosting both capacity and efficiency, and making up-to-date, affordable and quality casting production available to everyone,” stated DISA general product manager Bo Wolff Haugboelle.

The Disamatic C3 builds on the developer’s traditional appeal to foundries requiring both high-capacity production and high-speed operations. It reports now that the Disamatic C3 has been “a turning point for a number of small floor molding foundries in India and China, as the affordable and accessible vertical molding machine.” Customized for such foundries, the new molding process has allowed them to convert from jolt squeeze or manual molding processes to an automated vertical molding process. The result is evident in process productivity, enabling such foundries to achieve comparatively faster production of high-integrity molds, with low variability and minimal finishing costs.

The Disamatic C3 incorporates several technologies developed by DISA, in an attempt to make Disamatic process available to foundries of every size, worldwide. That is, according to the developer, the Disamatic C3 is DISA’s way of addressing directly the competitive challenges of the small and midsized foundries.

“We have seen how this particular market segment in both India and China struggles to obtain sufficient and qualified labor,” Haugboelle commented. “We know that many small and midsized foundries have limited resources to invest in new molding technology. We are aware that they fight to offer their customers a consistent casting quality, due to their manual processes.

“The Disamatic C3 is a machine designed to offer maximum capacity at minimum investment,” he continued, “delivering a high ROI over a long service life, even in cases where capacity is not fully utilized. Its automated systems not only produce accurate and consistent, high-quality castings, but are also based on straightforward principles, allowing generally skilled labor to handle all operation and maintenance in a safe working environment.”

The global network of DISA technical service and support is an additional factor in the success of the new product introduction.

“So whichever way you choose to look at it – and irrespective of foundry size – the introduction of the Disamatic C3 allows every foundry to be a DISA foundry. It is the Disamatic for everyone,” Haugboelle concluded.