The crew that takes the first step in converting the pattern to a casting is our molding department.
The crew consists of Cory Cesanek, Jeff Gruber, Tylor Hopkins, Corey Wendell, and Adam Yenca.
![Effort Foundry Molding Team](https://effortfoundry.com/wp-content/uploads/2022/01/molders.jpg)
“Set-up” to prepare pattern for filling with phenolic urethane bonded sand, this includes following the engineering instructions to put, chills, tile gating, and riser sleeves on the pattern prior to molding.
![Mixer Operator](https://effortfoundry.com/wp-content/uploads/2022/01/rinaldo.jpg)
“Mixer Operator” is the person assigned with filling the pre-setup pattern with the bonded sand. Sand is delivered through 2 – 250#/min high-speed auger mixers while air-injecting 1% binder to coat sand.
![Bonded Sand Molds](https://effortfoundry.com/wp-content/uploads/2022/01/mold.jpg)
“Knockout Personnel” After waiting for sand to harden (10-20 minutes), the bonded sand mold halves (cope/drag) are separated from the pattern. Each mold half (cope/drag) is washed (sprayed or brushed) with an alcohol refractory coating to enhance the cast finish.
![Mold](https://effortfoundry.com/wp-content/uploads/2022/01/mold-2.jpg)
The leader Cory and his crew are responsible for achieving the mold schedule daily from 30 to 50 molds a day depending on the mold sizes. Mold sizes can range from 12” x 12” to 72” x 72”.