Sand Casting

Large Parts, Broad Alloy Range, Lower Tooling Cost

Sand casting is the most flexible casting process — capable across a wide range of alloys and part sizes, with lower tooling investment than investment or die casting.

Process Overview

When sand casting is the right choice

Sand casting uses bonded sand molds to produce cast components across a wide range of sizes — from small fittings to multi-ton structural components. Tooling costs are low (patterns rather than hardened dies), making it practical for low-to-medium volumes, prototypes, and programs requiring frequent design changes.

Sand casting is the process of choice for gray and ductile iron components, large valve and pump bodies, heavy equipment castings, and programs where investment casting would be too expensive at low volumes.

Typical Volume

Low to medium (1 – 10,000 pcs/year)

Best For

  • Large or heavy components
  • Low-to-medium volumes
  • Wide alloy flexibility
  • Quick-turn prototype castings
  • Complex external geometry

Process Strengths

  • Lowest tooling cost of any casting process
  • Widest range of part sizes and weights
  • Flexible for design changes
  • Suitable for most ferrous and non-ferrous alloys
  • Good for prototype and short-run programs

Common Materials

  • Gray and ductile iron
  • Carbon and alloy steels
  • Stainless steels
  • Copper alloys (bronze, brass)
  • Aluminum alloys
  • Nickel alloys

Typical Components

  • Valve and pump bodies
  • Gearboxes and housings
  • Marine and subsea components
  • Heavy equipment castings
  • Industrial frames and bases
  • Custom prototype castings

Secondary Services

  • Pattern and core box design
  • Heat treatment
  • Machining and grinding
  • NDT inspection
  • Coating and painting

Related

Related materials, industries & products

Ready to discuss your sand casting program?

Send your drawing, material or process requirements, and program details. Oakmet will review and respond with next-step feedback.