Valve bodies are among the most critical components in fluid control systems, requiring high dimensional accuracy, superior surface finish, and excellent mechanical properties. In foundry manufacturing, two popular processes are commonly used for producing valve body castings — Shell Moulding and No-Bake (Air Set) moulding. Both methods have unique strengths and are suited for specific casting requirements. Let’s explore the differences and understand which process is best suited for valve body production.
Shell moulding is a precision casting process that uses resin-coated sand and heated metal patterns to form thin, rigid mould shells. These shells are then assembled to create the mould cavity.
The No-Bake process, also known as the air-set process, uses chemically bonded sand that cures at room temperature without heat. It is commonly used for larger and heavier castings or components requiring strong moulds.
Feature | Shell Moulding | No-Bake (Air Set) |
---|---|---|
Casting Size | Small to Medium | Medium to Large |
Surface Finish | Excellent (3.2–6.3 µm Ra) | Good (6.3–12.5 µm Ra) |
Dimensional Accuracy | Very High | Moderate |
Tooling Cost | High (metal pattern) | Moderate (wood/metal pattern) |
Production Rate | High | Low to Medium |
Best Suited For Precision castings, thin-walled valve bodies Large, heavy, or complex valve bodies.
The choice between Shell Moulding and No-Bake depends on your valve design, size, and application -
If your valve body requires tight tolerances, smooth finish, and thin walls, Shell Moulding is the ideal choice.
If your valve body is large, heavy, or requires multiple core assemblies, the No-Bake process offers better handling and structural integrity.
In many modern foundries, both processes are integrated — allowing flexibility to produce a wide range of valve castings depending on size and design.
At Raysons Shell Cast, we offer both Shell Moulding and No-Bake casting solutions under one roof. This dual capability enables us to supply valve bodies from 500 grams to 150 kilograms, maintaining top-quality standards across all sizes.
With advanced simulation tools, controlled sand systems, and ISO-certified processes, we ensure leak-proof, high-strength, and precision-engineered valve castings trusted by leading manufacturers across India and abroad.
Both Shell Moulding and No-Bake processes have distinct benefits. For high-precision and smaller valve bodies, Shell Moulding is superior, while No-Bake is ideal for large or complex valves. Partnering with a foundry that offers both ensures the best process selection, consistent quality, and cost-effectiveness — all delivered under one roof.