Michigan Occupational Information System
#015 - MOLD MAKER/COREMAKER (METAL)

Mold Makers make nonpermanent molds for the casting of metals. Coremakers make sand cores used in these molds. Molding jobs vary because of the different molding processes used such as sand, plaster, shell, and wax molding.

NATURE OF THE OCCUPATION

Machine Molders may:

Assemble patterns, follow boards, and foundry flasks (metal molding boxes consisting of two halves) on molding machine tables

Sift sand over patterns and fill foundry flasks with sand

Pack sand around pattern contours

Operate molding machines that compact the sand in flasks to form molds

Cut pouring spouts and holes in molds

Remove patterns from foundry flasks and repair defects in mold cavities such as cracks and broken edges

Reassemble both halves of the foundry flask so that molten metal may be poured into the mold cavities

Plaster Molders may:

Locate and mark parting (dividing) lines on a wood, metal, or plastic pattern using measuring instruments

Assemble the foundry flask on the molding table

Pour liquid plaster into the lower half of the foundry flask

Position the pattern in plaster up to the parting line and allow the mold to harden

Assemble both halves of the flask together and make depressions in the plaster around the lower half of the pattern

Brush a parting agent on the surface of the mold, pattern and flask

Pour liquid plaster into the upper half of the flask

Separate the halves after a specified time and remove the pattern

Join both halves of the mold together by positioning them in the flask and pouring liquid plaster over them

Coremakers may:

Make sand cores used in molds to form holes or hollows in metal castings

Force sand into the core pattern by hand or machines

Place reinforcing wires into the core to give it strength

Bake cores, remove them from the pattern, and cut hardened cores to size with saws

Tools used by Mold Makers and Coremakers may include:

In recent years, new organic chemicals and materials have been developed for bonding together molding sands. Also new are disposable patterns that are vaporized by molten metal. Flaskless molding machines, which can produce up to 300 molds per hour, are increasingly being used.

OCCUPATIONAL SPECIALTIES

Mold Makers and Coremakers may specialize in these areas:

518.361-010 MOLDERS make nonpermanent molds for the casting of metals.

518.682-010 MACHINE MOLDERS operate machines that form sand molds used in the production of metal castings.

777.381-034 PLASTER MOLDERS lay out parting (dividing) lines on patterns and cast plaster molds according to blueprints, sketches, and oral instructions. They apply knowledge of metal characteristics, pattern contours, and pouring procedures.

549.685-038 WAX MOLDERS tend semi-automatic wax molding machines that produce wax patterns used to cast complex parts requiring a fine surface finish.

518.685-026 SHELL MOLDERS tend machines that make shell molds used to produce metal castings. Shell molding is a process in which fine sand is mixed with resin and blown, dropped, or dumped onto a pre-heated pattern.

518.381-014 COREMAKERS

518.685-014 MACHINE COREMAKERS make sand cores used in mold to form holes or hollows in metal castings. They force sand into the core pattern by hand or by using machines. They may also bake cores, remove then from the pattern, and cut hardened cores to size with saws.

In addition to learning about these specialties, you may also find it helpful to explore the following MOIScripts:

WORKING CONDITIONS AND REQUIREMENTS

Mold Makers and Coremakers may work alone or with others. The work is done in foundries under the general supervision of a group leader or supervisor.

Working conditions vary depending on the place of employment and the kind of molding or coremaking performed. Workers may be exposed to dust, dirt, heat, noise, and sudden temperature changes when metal is being poured into molds. Heat and fumes have been greatly reduced in some foundries by the installation of improved ventilation systems.

The workweek of Mold Makers and Coremakers is usually 40 hours. They normally are scheduled for 8-hour shifts. However, overtime is common in some industries such as auto manufacturing.

Most Mold Makers and Coremakers are members of labor unions such as The International Union, United Automobile, Aerospace, and Agricultural Implement Workers of America (UAW) and The Glass Molders, Pottery, Plastics, and Allied Workers' International Union. Union members must pay dues.

You Should Prefer:

• Work which involves special processes and techniques

• Work involving the use of hand tools

• Work that is routine and organized

You Should Be Able To:

• Perform the same work repeatedly

• Understand how casting machines work

• Compare and see differences of lines, figures, and objects

• Follow set procedures and work accurately

• Make decisions based on measurable information

Math Problem You Should Be Able to Solve:

When hydrochloric acid is dissolved in water, it ionizes according to what chemical reaction?

Reading Example You Should Be Able to Read and Comprehend:

Hard chrome deposit can be rendered porous by mechanical or chemical or electrochemical methods. It is then called porous chromium, which consists of a large number of pits of controlled depth or network of cracks. The pits and channels help to retain the oil film adequately by rendering the chromium porous; the high wear resistance and low coefficient of friction of the plated metal are better utilized.

Writing Example You Should Be Able to Produce:

After examining a specific metal mold, prepare an analysis indicating any defects.

Thinking Skill You Should Be Able to Demonstrate:

Organizational skills and be detail oriented in preparing molds for the casting of metal.

EDUCATION AND PREPARATION OPPORTUNITIES

NOTE: On-The-Job Training provided by the employer or a High School Diploma or Equivalent or an Apprenticeship (usually three to four years of training beyond high school) may qualify a person for this occupation.

The following education and preparation opportunities are helpful in preparing for occupations in the MOIScript:

***SCHOOL SUBJECTS***

0200 ART , 0500 BUILDING TRADES , 0700 CAREERS , 0900 COMMUNICATIONS , 2200 MATH , 2300 METALS , 3200 TECHNICAL DRAWING , 3300 TECHNOLOGY

***VOCATIONAL EDUCATION PROGRAMS***

There are no Vocational Education Programs related to this MOIScript

***POSTSECONDARY PROGRAMS***

There are no Postsecondary Programs related to this MOIScript

           Search for a College and/or Instructional Program

***APPRENTICESHIP OPPORTUNITIES***

028 MOLD MAKER-METAL

Most people enter occupations within this MOIScript through an apprenticeship program. An apprenticeship program is a formal program that takes 3 - 5 years to complete with most of the time spent on the job.

Apprenticeship programs for this occupation usually include:

WHAT IS LEARNED ON THE JOB

WHAT IS LEARNED IN THE CLASSROOM

***MILITARY TRAINING OPPORTUNITIES***

There are no Military Programs related to this MOIScript

E-Learning Courses and Programs

OPPORTUNITIES FOR EXPERIENCE AND METHODS OF ENTRY

Because of the hazardous work in foundries, summer and part-time work are usually unavailable to persons under age 18. Experience may be gained through a formal apprenticeship program.

                School-to-Work opportunities include:

informal apprenticeships

mentorships

job shadowing experiences

touring a local Mold Maker and Coremaker employer

internships

volunteer work with a Mold Maker and Coremaker employer

community service work with an agency

Most Mold Makers and Coremakers enter the occupation through direct application to employers and, for highly specialized jobs, completion of an apprenticeship program. Assistance may be obtained from local unions representing Mold Makers and Coremakers, a local office of Michigan Works!, and newspaper want ads. In addition, you should access ad search the Internet's on-line employment services sites such as:

Michigan Talent Bank

America's Job Bank

Classifieds Employment

Yahoo! Careers

Michigan Works!

You should also enter an electronic resume on these on-line services.

EARNINGS AND ADVANCEMENT

Earnings of Mold Makers and Coremakers depend on specific job duties, extent of unionization, geographic area, and type of foundry. These workers are paid on an hourly and/or incentive basis. Those paid on an incentive basis generally have higher earnings.

Nationally, molding and casting machine operators, which include Mold Makers and Coremakers, earned median weekly wages of $430 or $10.75 per hour in 1998.

Mold Makers in a Michigan iron and steel foundry had base hourly wages (early 1999) of $12.83 to $14.00. Base rates for Coremakers ranged from $12.63 to $13.61 per hour.

In Michigan, for both union and non-union shops, the average hourly rate for all Mold Makers was $12.14 in early 1999. These workers may also receive a cost-of-living allowance.

Mold Makers and Coremakers who work the evening or night shift usually receive an additional 2% to 10% of their normal pay.

Mold Makers and Coremakers may receive paid vacations and holidays, sick leave, life, accident, and hospitalization insurance, and pension plans. Some workers and their dependents may receive dental or optical benefits.

Workers in the steel industry may also receive income protection plans that pay additional wages to workers losing or changing jobs because of technological changes. Benefits are paid for, at least in part, by employers.

Mold Makers and Coremakers may advance to positions such as casting inspector, group leader, or supervisor. In some cases promotions may be determined by a seniority based bidding system in which all jobs are given point values based on experience, skill, responsibility, and working conditions. For example, a mold closer may come from any job with a lower classification. Later, the mold closer may bid on and be trained for any position with a higher classification.

EMPLOYMENT AND OUTLOOK

Nationally, there were about 45,000 molding and casting machine operators employed in 1996. The employment of molding and casting machine operators is expected to grow more slowly than the average for all occupations through 2006. The increased use of automated equipment throughout the industry will limit employment growth. Foundry workers may experience layoffs or shortened workweeks when economic conditions are poor. The industry distribution for Molding and Casting Machine Operators looked like this:

About 1,825 Mold Makers and Coremakers are employed in Michigan. They all worked in manufacturing industries such as transportation equipment and primary metal and fabricated metal products. The places in which they worked turned out thousands of products, such as automobile parts, engine housings, pumps, agricultural machinery, machine tools, and aerospace parts.

Employment of Mold Makers and Coremakers in Michigan is expected to grow about as fast as average for all occupations through the year 2005. About 150 annual openings will be available with 50 due to growth and 100 due to replacement of workers who retire or leave the labor force for other reasons. Other openings will occur as workers change jobs or occupations.

One of the major developments in foundries has been the trend toward automation. There has been an increased use of automatic conveyors for sand delivery, mold handling, and cast finishing. Because of increased output and lower costs, foundries are using more automatic molding machines rather than hiring more workers. The demand for Mold Makers and Coremakers may also vary from year to year because this occupation is sensitive to changes in the economy.

MICHIGAN'S EMPLOYMENT OUTLOOK TO 2005

SOURCES OF ADDITIONAL INFORMATION

Printed occupational information is available upon written request from the sources below:

SUMMARY PROFILE

The occupation of Mold Maker/Coremaker can be summarized by the following:

MOISCRIPTS are Copyright 2003, Michigan Department of Career Development