Our Equipment & Capabilities
At HyCast, we are committed to delivering high-quality gray and ductile iron castings with precision, efficiency, and reliability. Our state-of-the-art foundry equipment ensures we meet the demands of a wide range of industries while maintaining strict quality standards. From advanced molding and melting processes to precise finishing and inspection, our facility is equipped to handle projects of all sizes and complexities.
Waterwalled
Cupola Furnace
The cupola furnace is a continuous melting shaft furnace designed for superior efficiency and material versatility. Unlike batch-type melters such as electric or rotary furnaces, our cupola can process a wide range of raw materials, including oily, wet, and contaminated scrap—materials that electric furnaces cannot safely accommodate. The natural refining process of the cupola allows contaminants to be reduced or eliminated as the metal melts into droplets before collecting in the well, resulting in cleaner, high-quality castings.
Isocure Core
Proces
The Isocure cold-box core process is a highly efficient method for producing sand cores. In this process, a special binder is mixed with sand just before being blown into a core box using compressed air. A curing gas is then injected into the core box, instantly hardening the core. The Isocure method is one of the most widely used core-making processes in North American foundries, providing fast cycle times, excellent strength, and reduced environmental impact.
Rotolift & Squeezer
Manual Molding
Our Rotolift and Squeezer molding machines are designed for low-volume production and custom casting projects. These manually operated machines accommodate a variety of flask sizes, allowing us to produce castings ranging from 1 to 100 pounds in both gray and ductile iron.
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(2) Rotolift – 26" x 36" (Largest Flask)
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(2) Squeezer – 17" x 17" (Largest Flask)
This process is ideal for specialized or short-run production, ensuring flexibility and customization for unique casting applications.
Induction
Melting
Our induction furnaces provide precise control over the metal composition, allowing for real-time adjustments before tapping. These refractory-lined crucibles feature water-cooled induction coils that generate heat through eddy currents, ensuring uniform melting and improved metallurgical consistency. This process enables us to maintain strict quality standards while optimizing efficiency and performance.
DISA Vertical
Molding
For high-volume applications, we utilize three DISA vertical molding machines, capable of producing ductile and gray iron castings with exceptional consistency and efficiency.
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(2) DISA Mark 5B – 21" x 26"
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(1) DISA Mark 4A – 20" x 25"
These machines deliver high-speed, automated production, making them ideal for industries that require large-scale, high-precision castings.
Shell Core
Process
Shell cores are made using resin-coated silica sand, which is blown into heated iron core boxes at approximately 550°F. The heat activates the resin, forming rigid, hollow cores with wall thicknesses ranging from 1/8 to 3/4 inch, depending on the casting’s size and complexity. This process produces high-precision cores with superior dimensional accuracy and surface finish, making it ideal for intricate castings. Our semi-automated vertical core machines deliver 20 to 60 cycles per hour, ensuring efficiency and consistency.
Automatic
Match-Plate Molding
For medium-volume production, we utilize three Beardsley and Piper (B&P) match-plate molding machines, offering flexibility in both ductile and gray iron casting.
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(1) B&P 16" x 20"
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(2) B&P 20" x 26"
These machines ensure high repeatability, improved dimensional accuracy, and cost-efficient production for a variety of casting needs.
Beyond casting, we provide a full suite of secondary processing services to enhance the functionality and durability of our products, including:
✔ Precision Machining – Ensuring tight tolerances and superior finishes.
✔ Coating & Surface Treatments – Improving corrosion resistance and longevity.
✔ Heat Treatment – Enhancing material properties for strength and performance.
At HyCast, we are committed to delivering precision, efficiency, and reliability in every casting we produce. With our advanced equipment, expert team, and comprehensive manufacturing solutions, we’re ready to meet the demands of your next project.
Value-Added Services