FUTAGAMI has been refining its green sand casting techniques for brass items since its establishment in 1897. This method employs an efficient molding process using sand as the primary material for the mold. It is referred to as “green” because the sand is recyclable, and it contains only clay, water, and sand without any chemical additives. It is a method that is environmentally friendly. Below is an overview of the production process.
1. Making Mold:
This method involves using casting sand molds, which are placed in a two-part molding box. A master mold is used to shape the sand, and a pour spout is added for molten brass. Sand coarseness is tailored to the product’s requirements.
2. Melting Brass:
Melting and pouring brass is the critical step in brass casting, with product quality hinging on the condition of the molten metal. Achieving the right copper-to-zinc ratio is crucial, and fine-tuning is necessary for each unique attempt.
3. Casting:
In this process, the molten brass is poured into the prepared mold. Any temperature changes cause subtle mixture changes. The flow speed and temperature of the molten metal into the mold vitally impact the product quality.
4. Breaking Mold
After casting, the molds are disassembled, causing the sand molds to collapse with noise, and the newly cast products fall out. After retrieving the hot items, they are left to cool overnight before final finishing work is done.
5. Finishing
*The photo on the left was taken by Lennaert Ruinen and cropped by IFJ Tradings. In a finishing workshop separate from the molding and casting area, finishing work, including cutting, polishing, and packaging, is carried out. Defective items are discarded here, and FUTAGAMI maintains extremely strict quality control.
