Capabilities - Maynard Steel Casting Company

Delivering Excellence in Steel Casting Since 1907

At Maynard Steel Casting Company, we firmly believe that the foundation of our success lies in the unwavering quality of our products. Our foundry specializes in the manufacturing of high-quality steel castings, designed to exceed the rigorous demands of the industries we serve.

For over a century, our primary focus has been crafting carbon and low-alloy steel castings ranging from 1,000 to 35,000 pounds casting weight. This remarkable versatility in our systems and facilities ensures sustainable solutions that adapt to a diverse range of industrial needs.

Advanced Steel Melting & Processing

Electric Arc Furnaces: Two furnaces with capacities of 15,000–50,000 pounds utilize basic linings for optimal steel processing and enhanced physical properties.
Bottom Pour Ladles: Capable of handling molten metal from 10,000 to 80,000 pounds, our ladles facilitate efficient treatment and pouring of larger castings, combining pour weights exceeding 65,000 pounds.

By employing cutting-edge clean steel technology, such as porous plug argon stirring and calcium, iron, or titanium wire treatment, we ensure precision and quality in every pour.

Precision Molding Techniques

Our mold preparation processes include green sand for smaller castings (under 1,000 pounds) and chemically bonded sand, often referred to as air-set or no-bake, for larger or specialty castings requiring specific surface or dimensional properties. We leverage ceramic tile gating systems and specialty facing sands to achieve top-tier results.

Which Molding Technique Fits Your Requirements Best?

AIR-SET or NO-BAKE process – This process is particularly advantageous for complex, high-precision components and lower-volume production. It offers several benefits when producing high-quality, large, and heavy low-alloy steel parts, including:

Superior dimensional accuracy due to the rigid, chemically bonded sand molds.
Excellent surface finish with minimal defects, which can reduce post-casting processing and machining costs.
Flexibility for larger or complex designs and for lower-quantity production runs.

GREEN SAND process – This process is uniquely useful for a variety of alloys, including low alloy steel, depending on the casting’s size, volume requirements, and complexity. It offers several benefits for producing high-volume, small, low-weight parts, including:

Part size: versatile for small to moderately sized castings.
Production volume: a more cost-effective option for medium- to high-volume production runs.
Relaxed tolerance requirements: suitable for many applications that have larger tolerances or reference dimensions.

Flexible Casting Solutions

To meet diverse casting requirements:

Flask Sizes: Ranging from 24′′×24′′ to 192′′×192′′ and 120′′×240′′.
Core Processes: Oil sand, shell, CO2, and no-bake techniques, supported by semi-automated core-making machines.

Commitment to Quality Assurance

From raw material selection to the final delivery, Maynard Steel Casting Company upholds the highest standards of quality assurance. Every casting reflects our commitment to excellence, reliability, and performance.

What to look for in a Foundry

The Gold Standard in Foundry Excellence – 12 Ways Maynard Steel minimizes the Total Cost of Ownership (TCO).

Expertise in Low-Alloy Steels – Does the foundry have proven experience with low-alloy steel casting, specifically using air-set/no-bake or green sand processes?
Advanced Design and Simulation Tools – DO they use 3D modeling and casting flow simulation software to identify design flaws early and enhance process reliability?
Industry Specific Experience – Are they familiar with your sector, such as mining, defense, heavy equipment, shipbuilding, aerospace, and others, so they understand your unique requirements?
Prototype and One-Off Capabilities – Can they produce single pieces or prototypes to help refine and optimize your design?
Capacity for Size and Volume – Do their facilities support the size, weight, and production volume of your parts?
Material Grade Expertise – Are they skilled in pouring the specific low-alloy steel grades your project demands?
Precision and Tolerances – Can the casting processes (techniques) meet your dimensional tolerance needs, especially for complex or high-precision components?
Integrated Secondary Services – Do they offer services like design for manufacturability (DFM), heat treatment, finishing, testing, and inspection to simplify your supply chain?
Quality Assurance and Certifications – Do they hold certifications such as ISO 9001 and provide thorough in-house testing, chemical, mechanical, and non-destructive (NDT)?
Material and Process Traceability – Is there a reliable system in place to track materials and processes for full traceability?
Location and Logistic Support – Are they positioned to minimize transportation costs and lead times, and can they support your logistical needs?
Clear and Responsive Communication – Do they offer expert, timely, and transparent communication to ensure smooth project and order management?

Interested in learning more about our capabilities?

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Our Capabilities