Casting our bells (Simulation)
See in this Computer Simulation what happens inside the mold when casting your bells.
Step by step to the final bell
Only first-class materials are used in our foundry. This starts with the molding sand, which must withstand the temperature of 1,100 ° C when pouring and ends with the secret metal alloy used.
For environmental reasons, our foundry does not use old and / or waste metal from the industry, because this metal can contain toxins and unwanted heavy metals. Our used metal is conditioned in conformable equipped facilities, so that the high quality requirements for the bells from Berger can be guaranteed.
A bell model as the basic form, sand as well as a mold box made of steel are required for the production.
First, the bell model is placed in the mold box. Subsequently, the gap between the bell model and the molding box is filled with fine sand. As a second step, the complete mold is turned over, the second mold box is closed to produce the inner mold (the core).
The bell model is now embedded in the sand in the second mold box. Now, the gating system is created for filling the mold with the liquid bronze.
Next, the mold box is reopened, and the bell model is removed. The bell shape of sand is now ready to be labeled and decorated.
After the labeling and decoration, the mold box is closed again and fixed with clips. This is necessary because the enormous forces are applied to the sand and the steel box when casting.
The molds are taken to the casting area and are now ready for casting. The finished sand mold is also fixed here.
In the background you can see the different basic models of all the different bells, which you can choose.
Now the time has come: The bells are poured at just over 1'100 ° C. The highlight of the day, even after more than 285 years, when "nothing" emerges to something new.
The cast molds are stacked and cooled overnight.
The next day, it will be shown whether the casted bells are flawless as soon as they are freed from the sand.
The used sand is 100% recycled. Because the sand has to withstand temperatures of more than 1'100 degrees, it turns black. When pouring, a little sand burns; The burned part is replaced by new sand.
Grinding dust, air pipes and sprues are melted again and recycled in that way.
After the "turning" the bracket is painted so that it does not rust. In the end the clapper is fitted. At last the bell can sound for the first time. A great moment!
The bells are now ready for sale at our factory cowbell shop or online shop. Of course, we can produce the right bell strap according to your wishes. We are also happy to deliver your personal bell directly to your doorstep.