Low to Medium Volume Aluminum Sand Castings
Every print is personally reviewed before we quote. You’ll hear back within 24 hours.
In-house pattern tooling and print review. Castings, machining and inspection through one accountable partner.
Casting Capabilities
Alloys, size range, tooling, processes, and inspection for aluminum sand castings.
| Aluminum Grades | 319, 356, A356, 357, 535 (Almag), 713 (Tenzaloy) Alloy selection based on strength, machinability, casting geometry, and application requirements |
|---|---|
| Part Size & Production Range | 0.1 lb to 250 lb typical casting weight No minimum order quantity. Prototype through repeat production supported based on part requirements. |
| Pattern Tooling | In-house pattern design and build Wood, urethane, and aluminum tooling options selected around geometry, volume, and production life |
| Casting Processes | Green sand and no-bake (airset) molding 3D printed molds available for rapid prototyping, design validation, and complex geometry Process selected based on part requirements, volume, and lead time |
| Heat Treatment | Heat treatment specified based on alloy, mechanical requirements, and customer specifications |
| Machining | Machining support through finished part requirements Critical features, datum structure, and inspection approach reviewed before production |
| Finishing & Surface Treatments | Anodizing, painting, powder coating, and other treatments coordinated when required Finishing selected based on application, environment, and customer specifications |
| Inspection, Testing & Documentation | Dimensional inspection with reporting, including first article layouts when required X-ray and liquid penetrant inspection available as required FAIR, PPAP, material certifications, and ISO 9001 quality documentation supported MIL-spec material, testing, and documentation requirements supported |
| Engineering & Program Support | Print review and manufacturability feedback before quoting and production Gating, riser, tooling, machining, and alternate manufacturing approaches reviewed when appropriate Each job is matched to the foundry partner best suited to its alloy, part size, and quantity |
Aluminum Castings
What We Watch For in Aluminum
Every aluminum print is checked for the problems that usually show up later, at the foundry, in machining, or in the field. These are the ones we look for first.
Shrink Porosity at Heavy Sections
Thick sections and junctions are where aluminum shrinks and leaves porosity. We review section transitions and feeding before tooling is built.
Pressure Tightness
Housings and fluid parts that must hold pressure need the right alloy, gating, and inspection plan. We flag it at quote, not after a leak test fails.
Mechanical Property Callouts
Properties from separately cast test bars and properties cut from the casting are very different requirements. We check which one the print calls for before we quote.
Tolerances vs. the Sand Process
Some print tolerances are tighter than sand casting can hold. We flag those features up front so they get machining stock instead of becoming rejects.
Thin Walls in Sand
Walls that are too thin for sand casting will not fill. We check minimum wall against the process and suggest changes before tooling, not after.
Request a Quote
Send your drawings, models, and requirements. You’ll hear back within 24 hours, and every print is personally reviewed before we quote.
What to Include
- PDF drawings and CAD models
- Alloy or grade and quantity
- Inspection, heat treat, machining, and documentation requirements if applicable
Looking for a Different Material?
Not sure aluminum is the right fit? We also support ductile iron, gray iron, steel, stainless steel, and other casting materials depending on your application.
