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No-Bake Sand Casting
Kormax provides no-bake sand casting solutions for customers requiring large, complex castings with excellent dimensional accuracy and surface finish. Unlike traditional green sand casting, which uses moisture to bind the mold, no-bake casting uses chemical binders to produce stronger molds for heavier, more intricate components. As part of our comprehensive sand casting services, we help customers select the most suitable no-bake sand casting process for their application.
What is No-Bake Sand Casting?
No-bake casting is a chemically bonded sand casting process in which sand is mixed with a resin binder and catalyst to create rigid molds that cure at room temperature. Unlike green sand casting, which relies on moisture and clay as the binding medium, no-bake molds provide greater strength and stability, making them effective for large, heavy, or complex castings with demanding dimensional requirements. The process is commonly used for low- to medium-volume production where tooling costs, component size, and design flexibility are key considerations.
Kormax supports customers throughout the no-bake sand casting process, covering alloy selection and design-for-manufacturing advice to manufacturing of components, machining, inspection, and ongoing supply. Our global network of foundries allows us to match each project to the facility best suited to its technical and commercial requirements.
Kormax’s No-Bake Sand Casting Capabilities
Kormax delivers no-bake sand-casted parts for large, complex, and heavy-section components across a wide range of industries. By combining experienced engineering support with our foundries in Turkey and India, we help customers select the right manufacturing approach based on component size, application, performance requirements, and production volume.
| No-Bake (Hard Sand) | |
| Size Range | 45 – 50,000 kg |
| Cost | Low |
| Design Freedom | Average |
| Casting Soundness | Depends on design & gating |
| Surface Finish | Average |
| Development Time | 4 weeks + |
| Production Time | 3 – 8 weeks |
| Foundry Locations | Turkey and India |
Casts Up to 50,000 kg
Kormax’s no-bake sand casting capabilities support large, heavy-section castings weighing up to 50,000 kg, making this process ideal for components that exceed the practical size limits of other sand casting methods. The process is commonly used for large industrial equipment, mining machinery, energy infrastructure, and other demanding applications.
Low Cost & Low-Cost Tooling
No-bake sand casting provides a cost-effective manufacturing solution by combining relatively low tooling costs with the ability to produce large, complex components efficiently. It is particularly good for low- and medium-volume production where minimizing upfront tooling investment while maintaining component quality is an important consideration.
Flexible Design Scope
Kormax helps customers maximize the design flexibility offered by no-bake casting, supporting complex geometries, heavy-section components, and custom configurations. Our engineering team provides design-for-manufacturing guidance to optimize performance, manufacturability, and overall project cost before production begins.
Sand Casting Process Steps
The foundry process from pattern to finished casting, as a one-page diagram.
Kormax No-Bake Foundry Network
Kormax partners with specialized foundries globally to deliver sand casting solutions for large, heavy, and high-volume components. Each foundry is vetted for capacity, material capability, and process reliability. By matching your requirements to the most suitable foundry, we ensure the right fit for demanding industrial applications while reducing supply risk.
Facility 1
Capacity:
Approx. 18,000 MT annual casting capacity
Single-piece weight range: 25 kg to 6,000 kg
Multi-site operation with 400+ employees
Specialisations:
High-integrity alloy and stainless steel castings
Carbon steel, alloy steel, duplex, and nickel-based alloys
Medium to large cast components
Raw and fully machined castings
Proven capability in critical applications
Relevant certifications:
ISO 9001
TUV Nord
Ideal for:
Oil and gas, energy, and heavy industry
Marine and offshore applications
Power generation and mining
Critical infrastructure and OEM equipment
Facility 2
Capacity:
Approx. 6,000 MT annual casting capacity
Single-piece weight range: 30 kg to 850 kg
Specialisations:
Alloy, carbon, and manganese steel castings
Valve, pump, and general engineering components
In-house metal and sand testing laboratories
Non-destructive testing (NDT) capability
Engineering support for custom casting development
Relevant certifications:
ISO 9001
Ideal for:
Valve and pump components
General industrial applications
OEM machinery and equipment
Quality-controlled casting projects
Facility 3
Capacity:
Approx. 15,000 MT annual casting capacity
Single-piece weight range: 12 kg to 5,500 kg
Specialisations:
Ductile and grey iron casting
Mechanical and industrial components
Consistent production capability
Support for subcontract and OEM manufacturing
Broad application across engineering sectors
Relevant certifications:
ISO 9001
Ideal for:
General engineering and industrial equipment
Power transmission systems
Electric motors and components
OEM machinery manufacturers
Kormax aligns your casting requirements with the right foundry partner, managing sourcing, production, and delivery end-to-end. This approach reduces variability and ensures reliable, high-quality outcomes.
OUR PROCESS
Our No-Bake Sand Casting Process at Kormax
Kormax manages every stage of the no-bake sand casting process, combining engineering expertise with qualified foundry partners to produce large, complex castings that meet demanding quality and performance requirements. Our structured approach helps ensure consistency, dimensional accuracy, and reliable project outcomes at every point.
STEP 01
Sand Mixing
Kormax works with qualified foundries that precisely blend high-quality sand with resin binders and catalysts, producing consistent mold material tailored to the component’s size and technical requirements.
STEP 02
Molding
A pattern is positioned within the prepared no-bake sand to create the required mold cavity, ensuring the dimensional accuracy and stability needed for large, complex castings.
STEP 03
Curing
The chemically bonded sand cures at room temperature, creating a rigid, high-strength mold capable of withstanding molten metal while maintaining dimensional integrity throughout casting.
STEP 04
Pattern Removal & Assembly
Once cured, the pattern is carefully removed and the mold sections are assembled with gating and riser systems to promote controlled metal flow and sound castings.
STEP 05
Pouring
Molten metal is poured into the prepared mold under carefully controlled conditions, allowing the cavity to fill while minimizing turbulence and casting defects.
STEP 06
Cooling
The hard sand casting is allowed to cool under controlled conditions to achieve the required metallurgical properties, dimensional stability, and mechanical performance before the component moves to finishing.
STEP 07
Shakeout
After solidification, the sand mold is broken away and the casting is removed for cleaning, allowing Kormax to prepare the component for inspection and finishing.
STEP 08
Finishing
Kormax coordinates fettling, machining, heat treatment, inspection, and surface finishing as required, ensuring each casting meets the specified dimensional, material, and quality requirements before delivery.
Why Choose Kormax for No-Bake / Hard Sand Casting Solutions
Kormax brings more than 75 years of engineered materials and casting expertise to no-bake sand casting parts and projects across mining, oil and gas, defense, OEM, aerospace, medical, and industrial markets. As an experienced sand casting solutions provider, we help customers manage technical risk, get the right foundry capability, and maintain supply continuity for large, complex, and performance-critical components.
End-to-End Sand Casting Solutions
Kormax provides a single partner for no-bake sand casting, managing design support, alloy selection, casting, machining, finishing, inspection, stockholding, and delivery.
Custom Capabilities
Castings are made to your drawings, sizes, profiles, and material grades, with design-for-manufacturing input to support complex components, prototypes, and production volumes.
Global Network of Top-Tier Foundries
Kormax works with a global network of qualified foundries, selecting the right manufacturing partner for each part to reduce risk and avoid single-foundry dependency.
ISO-Certified Management
Kormax operates an integrated management system certified to ISO 9001, ISO 14001, and ISO 45001, supporting quality, environmental, and workplace safety performance.
Secure, Reliable Supply
Consignment stock, buffer stock, scheduled supply programs, and dual-sourced foundries help Kormax support production continuity and reduce disruption for repeat no-bake casting requirements.
Competitive, Transparent Pricing
Multi-foundry tendering helps identify the best-value source, while low-cost tooling options and transparent quotations reduce upfront costs and help avoid unexpected surcharges.
Industries That Benefit from No-Bake Sand Casting
No-bake sand casting is appropriate for industries requiring large, heavy, or complex metal components with reliable mechanical properties and cost-effective tooling. Kormax helps customers select the right alloys, foundry partners, and manufacturing approach to meet the technical and commercial demands of each application.
Explore Other Sand Casting Services
Every casting project has different technical, production, and commercial requirements. If you’re unsure whether no-bake, green, or shell mold casting is the right choice, Kormax’s engineering team can help you select the most suitable process based on your component design, alloy, production volume, performance requirements, and no-bake sand-cast parts.
Green Sand Casting
Green sand casting uses moist sand molds to produce cost-effective components across a broad range of ferrous and nonferrous alloys, making it suitable for higher-volume production.
Shell Mold Casting
Shell mold casting uses resin-coated sand molds to produce intricate components with excellent dimensional accuracy, smooth surface finishes, and consistent repeatability for precision applications.
Need Help with Our No-Bake Sand Casting Solutions?
With more than 75 years of casting and engineered materials expertise, Kormax can support your no-bake casting project at every stage. When you need help with material selection, casting design, tooling, simulation analysis, or production planning for large or complex components, our experts are ready to help.
Partner with Kormax for No-Bake Sand Castings
As fourth-generation foundry specialists, Kormax brings expert knowledge of ferrous and nonferrous casting processes, global networking, and engineered material solutions. Our team understands the opportunities and risks involved in hard sand casting, helping customers access the right foundry capability, reduce supply risk, and achieve reliable outcomes for large, complex, and performance-critical components.
Contact Kormax for High-Quality Sand Casting Capabilities
Kormax combines technical casting knowledge, global foundry partnerships, and hands-on project support to deliver high-quality no-bake sand casting solutions for industrial customers. To discuss your next project or no-bake sand-casted parts, contact our knowledgeable team today.