Knowledge about sand casting and 3D sand printing machine (Part 1)

Sand casting is a traditional and widely used metal casting method that produces metal parts of various shapes and sizes using sand molds and casting patterns. This article will delve into the main components of sand casting: sand molds, sand casting patterns, and sand casting processes, as well as their significance and applications in modern manufacturing.

1. Sand casting mold

Sand casting is an important component used for metal casting. It consists of a mixture of sand and binder, which forms a mold that shapes the external and internal structure of the casting products. In sand casting, the mold is divided into two parts: the upper part (cope) and the lower part (drag), which together form the shape of the casting product.

The making process usually includes the following steps:

• Prepare the sample or prototype for molding.

• Make the upper and lower parts by placing the sample in the molding box and filling it with sand and binder, compacting it to form the mold.

• Remove the molding box, take out the mold and refine its surface to ensure smoothness and accuracy.

• Finally, assemble the upper and lower parts to form a complete mold, ready for casting.

2. Sand casting model

Are models or patterns used to create sand casting molds. They represent the specific shape and size of the casting product and play an important role in mold making. It can be made of wood, metal, plastic or other materials, depending on the requirements and manufacturing process of the casting product.

The process usually includes the following steps:

• Designing a pattern based on the design requirements and dimensions of the casting product, usually using a design drawing or CAD model.

• Making specific pattern models based on the design drawing or CAD model, usually using materials such as wood or plastic.

• Refining and processing the pattern models to ensure compliance with the requirements and suitability for sand casting.

• Finally, making sand casting molds based on the pattern models to proceed with the subsequent casting processes.

3. Sand casting process

Sand casting is a popular metal casting method, known for its low cost, versatility and wide application. It involves the use of sand molds and casting patterns to produce metal castings of various shapes and sizes. The basic steps of the sand casting process include mold preparation, casting, cooling, demoulding and finishing.

The main steps of the sand casting process are:

• Mold preparation: Making sand casting molds and preparing casting patterns.

• Casting: Melting metal materials (such as iron, aluminum, copper, etc.) and pouring them into the prepared mold.

• Cooling: Allowing the metal to cool and solidify in the mold.

• Demolding: Separating the casting from the sand mold.

• Finishing: Removing excess sand, flash and other impurities from the surface of the casting to achieve a smooth finish.

This technology is suitable for the production of small to large metal casting products, providing cost-effective solutions for many industries, including automotive, machining, aerospace and more.

In modern manufacturing, this technology continues to evolve and improve to meet changing needs and challenges. By optimizing the designkế khuôn, lựa chọn vật liệu và quy trình sản xuất, sẽ tiếp tục đóng vai trò quan trọng trong việc cung cấp các giải pháp đúc chất lượng cao, hiệu quả về kinh tế cho các ngành công nghiệp khác nhau.

3D sand mold printer

Reinventing Metal Casting with Sand Mold 3D Printers

Our revolutionary sand-jet 3D printer enables your foundry to overcome the traditional limitations of casting and embrace the future of digital manufacturing.

By printing complex sand molds directly from CAD data, it eliminates the need for templates and tooling to create complex geometries that are not possible with traditional mold making methods.

Reduce new product development time by 70% through rapid prototyping and accelerate design validation.

Enable on-demand production in small quantities without high tooling costs. With minimal waste, 100% sand recyclability and inventory efficiency, it also aligns with sustainability goals.

Bring unprecedented flexibility, versatility and capability to your foundry with advanced sand mold 3D printing systems specifically designed to help shape the next generation of metal casting.

What is a Sand 3D Printer?

A sand 3D printer, also known as a sand jet 3D printer for die casting, is a type of 3D printing technology specifically designed to create sand molds and cores used in metal casting processes. These printers are not intended to create final parts or objects, but instead to produce the molds and cores needed to cast complex-shaped metal parts.

Here’s how a sand 3D printer typically works:

Layering stage: The printer deposits a thin layer of sand powder (usually fine silica sand) onto the print bed.

Ink jet printing: A print head or similar mechanism selectively applies a liquid binder (usually a water-based adhesive or resin) to the sand powder. This binder bonds the sand particles together in specific locations, essentially “gluing” them together.

Layered Construction: Steps 1 and 2 are repeated, with successive layers of sand and binder applied on top of each other. The 3D printer traces the digital 3D model to build up the shape of the sand mold or core layer by layer.

Curing: After the printing process is complete, the sand mold or 3D printed core is allowed to dry and harden. This may include drying out the binder or allowing it to dry naturally.

Post-printing processing: After hardening, the sand mold or 3D printed core is carefully removed from the excess sand powder, cleaned, and prepared for use in the metal casting process.

The primary purpose of a sand mold 3D printer is to produce detailed and complex molds and cores for casting applications. These molds and cores are used to define the shape of the metal part being cast. Molten metal is poured into the mold, and as it cools and solidifies, it takes the shape of the sand mold or 3D printed core.

Sand 3D printing offers advantages such as faster prototyping, shorter lead times, and the ability to create complex geometries that can be difficult or expensive to achieve with traditional molding techniques. It is commonly used in industries such as automotive, aerospace, and foundries where complex and precise metal parts need to be produced through casting processes.

Sand 3D printing, also known as binder jetting (learn more) or sand 3D printing, is a technology used primarily in the casting and foundry industry to create complex molds and cores for metal casting processes.

Sand 3D printing offers many advantages in the casting and foundry industry, including the ability to create complex and optimized internal geometries, reduced tooling costs, faster prototyping, and improved casting quality. It is a valuable technology for industries that require precision and flexibility in their casting processes.

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