How does vertical moulding work?

Vertical moulding is a very efficient way to quickly and automatically create a string of flaskless high precision moulds that are vertically parted and poured.

The moulding chamber is filled with sand from above. One pattern plate is mounted on the pressure plate (left)  and the other plate is mounted on the swing plate (right).	The pressure plate and the swing plate move towards each other to compress the sand and form the mould. The pattern plates create impressions on each side of the mould.	The swing plate moves out and then swings up, allowing the mould to be pushed out of the chamber.

The pressure plate extends further, gently pushing the new mould into contact with the line of previous moulds (“mould string”) which then moves one position closer to the pouring zone. Each new mould’s leading edge meets the previous mould’s trailing edge to create a cavity that will be filled with molten metal.	The pressure plate starts to return to its original position.	The swing plate returns to its original position, closing the chamber. Any cores required are inserted in the trailing edge of the new mould. The cycle begins again.

Vertical moulding produces hard, accurate moulds at outstanding speeds. DISA introduced vertical moulding to the market with the DISAMATIC® in 1964. For decades, it has offered the lowest cost-per-casting for medium-to high-volume production.

Since then, DISA has installed over 1,735 vertical moulding machines globally, with new DISAMATIC models at the cutting edge of high performance moulding. With the newly developed DISAMATIC C- lines, lower volumes can now be addressed cost-efficiently too.

DISAMATIC vertical moulding lines achieve very high moulding rates of up to 555 moulds per hour without cores and up to 485 moulds per hour with cores.

Fast pattern changing equipment means vertical moulding is also flexible and economical for shorter series production at speeds down to 120 moulds per hour with cores. With DISA’s Automatic Pattern Changer (APC), changing pattern plates only halts the moulding line for one minute. Changes with the manually operated Quick Pattern Changer (QPC) can be as short as three minutes.

A simple and proven core setting process makes creating hollow parts straightforward. DISAMATIC vertical machines are compact and offer a modern, safe working environment.

Vertical moulding is suitable for ferrous, aluminium, brass/bronze and steel castings with mould sizes from 500 x 400mm up to 1200 x 1050 mm. It is applied extensively in the automotive industry for the high volume production of parts like brake calipers, brake discs and exhaust manifolds. Numerous other applications run from domestic frying pans and pipe fittings to fire hydrants and manhole covers.