Sand casting is one of the most versatile and cost-effective metal casting methods, capable of producing medium-to-large components with complex geometries. It is widely used in automotive, industrial, energy, and aerospace sectors for both ferrous and non-ferrous metals.
Sand casting, also known as sand mold casting, involves creating a mold from sand aggregate and pouring molten metal into the cavity to form a part. Key advantages include low tooling costs, flexibility in part size and shape, and suitability for medium to low volume production.
Process Overview:
Pattern Making: Crafting a replica of the part in wood, metal, or plastic.
Mold Making: Packing green sand or chemically bonded sand around the pattern to form the mold.
Core Making: Producing cores for internal cavities or undercuts.
Melting & Pouring: Pouring molten metal into the prepared mold.
Cooling & Shakeout: Allowing the metal to solidify, then breaking the mold to remove the casting.
Finishing: Removing gates and risers, shot blasting, and surface finishing to meet tolerances.
Gray Cast Iron (HT100–350): Excellent castability, machinability, and vibration damping; used in automotive bases, engine blocks, and industrial machinery.
Ductile Iron (QT400–450, ASTM A536 65-45-12, DIN GGG40): Superior strength, toughness, and impact resistance; ideal for load-bearing components.
Aluminum Alloys (A356, A413.0, ZL102): Lightweight and corrosion-resistant, suitable for housings, structural frames, and consumer products.
Carbon & Stainless Steel: High-strength and corrosion-resistant parts for industrial, energy, and aerospace applications.
All materials can meet international standards for quality, traceability, and performance.
Cost-effective for large or medium-sized parts: Sand patterns are cheaper than permanent dies.
Design Freedom: Capable of producing very complex shapes that are difficult with machining or die casting.
Material & Size Flexibility: Suitable for a wide range of ferrous and non-ferrous metals, from kilograms to tons.
Comparison Table:
| Feature | Sand Casting | Die Casting | Investment Casting | Forging |
|---|---|---|---|---|
| Part Size | Medium to Large | Small to Medium | Small to Medium | Small to Large |
| Complexity | High | Medium | Very High | Medium |
| Tolerance | ±0.5–1.5 mm | ±0.1–0.5 mm | ±0.05–0.2 mm | ±0.2–0.8 mm |
| Surface Finish | Medium | Smooth | Excellent | Good |
| Tooling Cost | Low | High | Medium | Medium |
| Volume Suitability | Low–Medium | High | Low–Medium | Medium–High |
Automotive: Engine blocks, cylinder heads, gearbox housings, brake discs.
Heavy Machinery & Industrial: Pump housings, valve bodies, machine tool bases, large gears.
Energy & Power Generation: Turbine housings, wind turbine hubs, impellers.
Aerospace: Structural frames, turbocharger housings.
15+ years of experience producing custom sand castings with high precision.
Expertise in gray iron, ductile iron, aluminum, carbon & stainless steel.
Comprehensive services: design support, prototyping, casting, finishing, CNC post-processing.
Advanced quality control: material certificates, dimensional inspection, surface treatment verification.
Commitment to green production: energy-efficient processes, digitalization, and smart manufacturing.
Tailored solutions: integrate threaded inserts, rib structures, and unique surface treatments directly in casting to reduce secondary operations.
A1: We can cast components ranging from a few kilograms up to several tons, depending on design and material.
A2: Through precise pattern making, mold control, CNC post-machining, and finishing processes such as shot blasting and plating.
A3: Yes, we have extensive experience with a wide range of ferrous and non-ferrous alloys, following international standards.
A4: Prototypes are typically delivered within 2–4 weeks, while mass production depends on part complexity and order volume.
Send us your drawings (STEP, DWG, PDF) for a free DFM review and quote.
