The core/mold has desirable characteristics for producing high quality castings.
 There is a range of casting requirements that lies somewhere between the process advantages of sand, investment, permanent mold and die casting. When it comes to balancing the cost of tooling and production with volume and quality requirements, it can be difficult to find the right fit without making sacrifices. We believe the Alpha Process fills a void among these differing casting processes.
This process is a variation of a little used foundry process known as the Shell Molding Process. The Shell Process (which is widely used in foundry core production) uses a special resin-coated sand that becomes very hard and rigid when injected and baked in a heated core or mold pattern.
The resulting core/mold has desirable characteristics for producing high quality castings. The rigidity of the baked shell sand provides consistency in dimensional accuracy, and the extreme grain fineness of the sand provides very good surface finish.
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The Alpha Process takes advantage of these characteristics while utilizing less shell sand and creating a mold/core that is less expensive, easier to remove, and provides better venting of mold gasses during pouring, which also minimizes porosity defects.