Not an expert, but, you can only take so much out of the cost of tooling before you experience problems, which in turn cost more that using the proper materials of construction in the first place.

Trying to squeeze every penny out of the cost of doing business is not always wise. Buy a bigger press or make smaller parts.

As a last resort, you might consider hiring a consultant to streamline you processes and equipment.

Free advice is usually not very good. The advisors have no stake in the outcome.

Yes I agree with you that every penny saved may not be helpful but here mute question is to look for alternate material which may be cost effective and light in weight to give support to machine for better efficiency.I know light weight materials available like Mg alloy plates but definitely looking for non metallic ones as well because penny saved is penny earned in the long run.

Thanks for your participation and advise on these lines welcome.

Can THIS be of any help to you.

Thanks Joshi for advise. I know these but am interested in non metallic alternative possibly if its able to give strength and cost benefit.

Explore using urethane foam reinforced FRP. In marine field it is used in making lifeboat, yacht. Very strong & very light.

Have you tried backing up bonded wood match plate with aluminium sheeting of suitable thickness?

I take it your make a cope and a drag unit in match sets. If each Cope and Drag are being fill with one ton of green sand that's a fairly large box. Wood as you have learned will buckle under the loading caused by the squeeze and then added jolt to it and your in trouble. My suggestion is to look into cast plates that are designed for such use. Several Molding machine companies supply these for their units. Herman, Hunter, Simplicity, etc, etc. If your using someones machine I would suggest speaking to their engineering department. Other wise you may need to look into after market suppliers of these unit. Foundry magazine out of Chicago Ill might be able to offer you leads or the American Foundry Mens society.

Fixit

These options are already available but am exploring more durable,sound and cost effective alternative.Thanks for sharing you views.

I hope your not making parts for me. Molding operations are suppose to be done in a manner that is cost effective for sure. But, to get good parts from a mold you need to make good molds, to get a good mold you need proper equipment. Good luck!