Shell mold casting or shell molding is a metal casting process in manufacturing industry in which the mold is a thin hardened shell of sand and thermosetting resin binder, backed up by some other material. Shell molding was developed as a manufacturing process during the mid-20th century in Germany.

Shell mold casting is particularly suitable for steel castings under 20 lbs; however almost any metal that can be cast in sand can be cast with the shell molding process. Also much larger parts have been manufactured with shell molding. Typical parts manufactured in industry using the shell mold casting process include cylinder heads, gears, bushings, connecting rods, camshafts and valve bodies.

Properties and Considerations of Manufacturing by Shell Mold Casting:

  • The internal surface of the shell mold is very smooth and rigid.
  • Manufacturing with the shell mold process also imparts high dimensional accuracy. Tolerances of .010 inches (.25mm) are possible. Further machining is usually unnecessary when casting by this process.
  • Shell sand molds are less permeable than green sand molds and binder may produce a large volume of gas as it contacts the molten metal being poured for the casting.
  • The expense of shell mold casting is increased by the cost of the thermosetting resin binder, but decreased by the fact that only a small percentage of sand is used compared to other sand casting processes.
  • Shell mold casting processes are easily automated.
  • The special metal patterns needed for shell mold casting are expensive, making it a less desirable process for short runs. However, manufacturing by shell casting may be economical for large batch production.