Sand Casting – Production of Aluminium, Bronze & Brass Castings for Industry
Sand Casting – A Proven Technology for Your Production
Aluminium (aluminum) sand casting is one of the most widely used foundry methods across the machine‑building, automotive and aerospace sectors. Thanks to competitive cost per part, production flexibility and the ability to produce complex geometries, this technology is ideal for single prototype parts as well as industrial series.
Sand Casting Technology – Repeatability in Production
Precise and Efficient Series Production of Castings
For years our foundry has refined the sand casting process, delivering durable, precise and repeatable metal castings for multiple industries. With modern technologies and advanced quality control, we supply castings with high mechanical strength and dimensional accuracy, tailored to the requirements of the automotive, machinery, aerospace and energy sectors.
Production begins with preparing sand moulds made from a carefully selected mix of quartz sand and binder to ensure faithful reproduction of details. In many projects we also use precisely made cores to achieve intricate internal structures.
Our sand casting technology provides
Series production of castings with high repeatability and consistent quality
Ability to cast complex shapes and internal geometries
Castings tailored to technical and mechanical performance requirements
Post‑casting finishing and CNC machining of aluminium castings for dimensional precision and surface quality
After pouring, every component undergoes quality control and mechanical processing so it meets technical standards and is ready for industrial use. With experience, modern production methods and a flexible approach, we deliver castings that meet the highest technological and quality standards. On request we provide heat treatment of aluminium castings, strength testing and dimensional inspection (CMM), and we support rapid changes through our in‑house toolroom for mould design and adaptation.
We Apply Core‑Making for Accurate Castings and Control of Casting Structure
Modern Core‑Making Technologies in Our Foundry
We implement advanced core‑making processes that play a key role in shaping the internal geometry of sand castings. With precisely manufactured cores and strict control of the casting structure, we ensure dimensional accuracy, uniformity and optimal mechanical properties of finished components.
Depending on the application of the castings we use different types of moulds and cores:
🔹 Split moulds with reusable patterns – used in series production to maintain high repeatability of castings.
🔹 Non‑split moulds on single‑use patterns – applied in more complex projects where faithful reproduction of intricate details is critical.
Thanks to precise control of the composition and properties of moulding sands, and modern techniques of core compaction and stabilisation, we ensure structural consistency and a high‑quality surface of the castings.
Every stage of core‑making and moulding in our foundry is monitored to ensure reliability and durability of the final products. Tight control of the casting structure allows us to eliminate defects and achieve top technical standards demanded by automotive, aerospace, energy and machine‑building industries.
With experience, modern technologies and meticulous inspection of each casting, we deliver durable, robust and precisely fitted components that perform in the most demanding applications.
We Perfect the Moulding Process for Top Quality and Precision of Castings
Mould Shaping That Ensures Repeatability and Dimensional Accuracy
Moulding is one of the most important stages of sand casting, directly influencing quality, strength and dimensional precision. We treat this process with utmost care, because a correctly shaped mould is the key to excellent structure and repeatability of the finished casting.
The foundation of successful moulding is selecting the right moulding sand. Depending on the part and its application, we use different sand blends that undergo advanced preparation, mixing and compaction. Each blend must meet strict requirements for strength, plasticity and gas permeability to ensure uniform solidification and to avoid casting defects.
In our moulding shop we use modern systems for automatic dosing and compaction of moulding sands, which preserve high precision for every casting. Depending on the project we apply:
🔹 Self‑setting (no‑bake) moulding sands – ideal when high stability and dimensional accuracy are required.
🔹 Thermosetting moulding sands – enabling excellent mechanical properties and an outstanding surface finish.
Control of casting structure – every detail matters
A key aspect of moulding is the control of the casting structure, which we perform at every stage. A high‑quality mould guarantees that the casting is free from imperfections, porosity and uncontrolled shrinkage. Our advanced moulding methods produce components with a uniform structure, free of cracks and material defects—crucial in automotive, machine‑building, energy and aerospace applications.
Modern moulding means not only quality but also efficiency
Thanks to process automation and continuous control of moulding parameters, we can significantly accelerate production, minimising the risk of errors and increasing product repeatability. The outcome is high-precision sand castings with outstanding dimensional accuracy, fully compliant with rigorous quality standards and technical requirements.
There is no room for compromise in our foundry — every stage of moulding is executed in line with industry best practices and our long-standing expertise. It is this blend of precision engineering and modern sand casting technology that makes our castings reliable, durable and ready to perform in the most demanding industrial environments.
We supply products from our aluminium foundry with streamlined process documentation that includes the engineering drawing and the technical conditions for manufacture and acceptance. Aluminium sand castings from sand moulds are produced across a broad weight and mould‑box range matched to your project requirements.
Charge materials and melt preparation
Which aluminium alloys do we use for pressure die casting?
| Aluminium Alloy | Main Alloying Elements | Properties | Typical Applications |
|---|---|---|---|
| EN AC-42000 | Silicon (6–8%), Magnesium (0.2–0.5%) | Good fluidity, high corrosion resistance, medium strength | Automotive parts, engine housings, machinery components |
| EN AC-46200 | Silicon (9–11%), Copper (2–4%) | High strength, very good castability, moderate corrosion resistance | Engine blocks, structural parts, fittings |
| EN AC-46500 | Silicon (10–13%), Magnesium (0.05–0.5%) | Excellent castability, good corrosion resistance, stable dimensions | Electronics enclosures, automotive components, home appliances |
| EN AC-47100 | Silicon (11–13%), Copper (1.0–2.5%) | Very good fluidity, high mechanical strength | Automotive parts, engine components, electrical equipment |
| EN AC-51300 | Magnesium (4.5–5.5%), Silicon (0.4–0.8%) | Excellent corrosion resistance, high tensile strength | Automotive, structural and engineering components |
Frequently Asked Questions – FAQ
Most Frequently Asked Questions About Sand Casting
What are the main advantages of sand casting at our foundry?
Sand casting is a proven and cost‑effective technology for producing metal castings with high repeatability and dimensional accuracy. By using modern moulding sands and process automation, we deliver complex shapes that meet industrial requirements in sectors such as automotive, energy, aerospace and machinery. Post‑casting CNC machining, heat treatment and quality control are available to achieve the specification you need.
Which metals do we cast with the sand casting method?
We specialise in aluminium, bronze and brass sand castings. Each alloy is selected to match the required mechanical properties, wear resistance and operating conditions of the final component.
What are the stages of the sand casting process?
The process starts with preparing high‑quality sand moulds using quartz sand and specialist binders. After pouring liquid metal and solidification, the casting is knocked out, cleaned and subjected to mechanical processing to achieve the required dimensional and aesthetic parameters. Every finished component undergoes rigorous quality inspection to meet technical standards and industrial requirements.
What moulding technologies do we use in our foundry?
We use modern moulding systems that ensure high accuracy and dimensional stability of the castings. These include self‑setting (no‑bake) sands and thermosetting sands, which deliver exceptional precision and surface quality. Thanks to automation, our castings offer consistent repeatability and high strength.
What is core‑making and why is it crucial in sand casting?
Core‑making enables the formation of complex internal channels and cavities that are impossible to achieve with moulding alone. We apply both split‑core and single‑piece solutions to precisely reproduce geometry and to deliver optimal mechanical performance of the casting.
How do we control the quality of sand castings?
Each casting passes a multi‑stage quality workflow that includes:
✔ Analysis of moulding‑sand composition and properties
✔ Monitoring of the casting structure to detect potential defects
✔ Precise dimensional inspection (including CMM on request) and strength testing
These measures help us eliminate gas porosity, shrinkage and other defects, ensuring reliability and long service life.
What dimensions and weights can we produce?
We manufacture aluminium sand castings across a wide range of sizes and weights, from prototypes to small and medium series. Share your drawing and technical conditions with us and we will confirm feasibility and propose the optimal tooling and process route.
Which industries use sand castings from our foundry?
Our sand castings are used in many sectors, including:
✔ Automotive – structural components, housings, powertrain parts
✔ Aerospace – lightweight, durable elements of airframe systems
✔ Energy – turbine housings, enclosures, transmission components
✔ Machinery – machine parts and components for production lines<akapit>
What benefits does automation of the moulding process bring in our foundry?
Automation ensures repeatable quality without surface defects and distortions. With modern systems for mixing, dosing and compacting moulding sands we reduce the risk of human error, shorten production time and ensure optimal mechanical properties of the castings.
Do we provide technical documentation with the castings?
Yes. Every casting is supplied with streamlined technological documentation that includes the part drawing and the technical conditions for manufacture and acceptance. On request, we add inspection reports (e.g., dimensional inspection, material/strength tests) and we can handle post‑casting CNC machining, heat treatment and mould/tooling adaptation in‑house.