Frequently Asked Questions
About Sand Casting and Foundry Services
General Sand Casting Questions
Sand casting is a process where sand is packed around a pattern to form a mold, and molten metal is then poured into that mold to create a casting.
Sand casting can be used for a wide range of parts, from simple to very complex shapes.
Sand casting tooling is relatively inexpensive when compared to permanent mold or die casting tooling.
Production and Capabilities Questions
Production volumes can range from a single piece using airset molding to hundreds of thousands of pieces on the automated molding machines.
On the automated molding line, casting weight can range from a fraction of a pound up to 10, with part sizes from 1″ square up to 30″x40″. The airset line can accommodate parts weighing up to 100.
Whether a sand casting requires machining is determined by its end use. Tight tolerances, smooth surface finishes, threading, or drilled holes may lead to machining being required.
Yes, both prototype and production runs can be supported through sand casting processes.
Material and Casting Questions
Aluminum Sand Casting FAQ
The primary difference is in composition. Bronze is primarily copper and tin, while brass is copper and zinc.
Bronze offers better corrosion resistance, strength, and wear properties, while brass is generally easier to cast and machine.
Bronze is typically the preferred choice for bearings, marine, or high-wear applications. Brass is typically used for fittings and parts where machinability is a priority.
Bronze and brass castings are used across a wide range of industries, including Fire Protection, Electrical, Automotive, Industrial Machinery, Construction, Infrastructure, Marine, Hardware, and Plumbing.
A core is required when a casting has internal cavities, undercuts, or features that cannot be drawn from a mold half.
A draft of 1–3º on the pattern is typically required to allow for ease of pattern removal from the sand. Fillets reduce stress concentrations and improve metal flow in the mold.
Bronze or Brass Sand Casting FAQ
The primary difference is in composition. Bronze is primarily copper and tin, while brass is copper and zinc.
Bronze offers better corrosion resistance, strength, and wear properties, while brass is generally easier to cast and machine.
Bronze is typically the preferred choice for bearings, marine, or high-wear applications. Brass is typically used for fittings and parts where machinability is a priority.
Bronze and brass castings are used across a wide range of industries, including Fire Protection, Electrical, Automotive, Industrial Machinery, Construction, Infrastructure, Marine, Hardware, and Plumbing.
A core is required when a casting has internal cavities, undercuts, or features that cannot be drawn from a mold half.
A draft of 1–3º on the pattern is typically required to allow for ease of pattern removal from the sand. Fillets reduce stress concentrations and improve metal flow in the mold.
