Sand casting is the basis of casting technology and has been common practice for thousands of years. It is the go-to metal casting process for flexibility in producing shaped parts weighing from a few grams to hundreds of tons. The versatility and cost effectiveness of sand castings means it is a viable process even for low volumes because of low tooling costs. Almost all parts configuration made using another metal casting process can be reduced to a pattern and manufactured using the sand casting process.
A pattern of the required finished product along with the metal delivery system, comprising gates and risers, is developed using either hardwood, urethane, metal, or foam. Sand is then packed with a bonding agent around the pattern to give an imprint of the required casting shape. Molten liquid metal is poured into the remaining cavity which is left to cool allowing the metal to solidify. Once cooled, the metal cast is separated from the sand and the delivery system, leaving the desired part.
Internal passageways and cavities can be included in the sand casting by adding cores. This makes sand casting a popular choice for pump and valve applications. ASC produces sand castings up to 2.5 m linear with a shipped weight of up to 4,000 kg.
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