Aluminum Sand Casting


This sand-casting process offers a versatile and economic option for high-volume, complex runs, as well as low-volume, customized runs. Sand casting is the process of pouring molten aluminum into a mold cavity formed in sand that is bonded by clay and water. Sure Cast produces castings ranging in size from ounces up to 60 pounds.

  • FDNX Flaskless Molding Machine
    • Accommodates any 16” x 20” pattern or smaller with adapter
    • Ideal for switching from manual molding to automatic molding
    • Aeration Sand Filling Technology for producing high quality castings
    • Low Noise and Energy
    • Replace multiple jolt squeezers!
  • Roto Lift line with the flasks ranging from 14×23 to 24×24 inches
  • Skilled molders and sand control with regular laboratory test to assure a fine casting finish


No-bake sand casting, also known as air-set sand casting or chemically bonded sand casting, is a versatile and modern method for producing aluminum castings. Unlike traditional green sand casting, this process doesn’t require baking the molds, making it more time-efficient. The process begins with creating a pattern, typically made of wood, plastic, or metal, that represents the final shape of the casting. The mold is then prepared using a two-piece flask, with one half called the cope and the other called the drag. A mixture of silica sand and a chemical binding agent is used to form the sand mold around the pattern.

The sand mixture is cured at room temperature, allowing the chemical binder to harden and provide the necessary strength to withstand the molten metal during pouring. Once cured, the pattern is removed, leaving a negative impression in the sand mold. If required, cores can be inserted into the mold to create internal features. The molten aluminum is poured into the mold, filling the cavity. After cooling and solidification, the mold is opened, and the sand is broken apart to reveal the solid aluminum casting. The casting is then finished by removing excess material and performing additional processes like machining and surface treatments.

No-bake sand casting offers benefits such as greater dimensional accuracy, the ability to produce complex shapes, and excellent surface finishes. It is widely used in various industries for low to medium volume production runs and is suitable for casting a range of aluminum alloys. The process provides a cost-effective and efficient alternative to traditional green sand casting, making it a popular choice for various aluminum casting applications.


Aluminum sand casting is a widely used process for creating complex metal parts, and sand cores play a crucial role in achieving intricate designs and internal features. Whether you are a seasoned professional or just starting in the world of sand casting, understanding how to use sand cores effectively is essential for successful and efficient aluminum casting.

1. What are Sand Cores?
Sand cores are precisely shaped components made from sand mixed with a binder that is used to create hollow spaces or internal features in aluminum castings. These cores are placed inside the pattern cavity before pouring molten aluminum to form the desired shape.

2. Benefits of Sand Cores in Aluminum Casting
Using sand cores in aluminum sand casting offers several advantages, including:

  • Complex Geometry: Sand cores enable the production of intricate internal structures, such as hollow passages, undercuts, and varied wall thicknesses.
  • Design Flexibility: They allow for innovative designs without compromising the structural integrity of the final product.
  • Cost-Effectiveness: Sand cores are relatively inexpensive compared to other manufacturing methods, making them ideal for small to medium-sized production runs.
  • Time Efficiency: Incorporating sand cores reduces the need for secondary machining, saving time during the manufacturing process.

3. Sand Core Design and Production
Creating effective sand cores involves a well-thought-out design and production process. Our experienced team ensures the following steps are meticulously followed:

  • Design Analysis: Our experts carefully analyze your product’s design requirements to determine the appropriate core geometry and material selection.
  • Core Box Production: Once the design is finalized, we manufacture precision core boxes that define the core’s shape and dimensions accurately.
  • Sand Mixing and Binder Application: High-quality sand is thoroughly mixed with a suitable binder to enhance the core’s strength and resistance to heat and molten aluminum.
  • Core Assembly: The sand mixture is packed into the core box, and when cured, the sand core is assembled, ready to be placed inside the pattern.
  • Quality Control: Our rigorous quality control ensures that every sand core meets the required specifications and tolerances for a successful casting process.

4. Implementing Sand Cores in Aluminum Casting

To utilize sand cores effectively in aluminum sand casting:

  • Proper Positioning: Position the sand core correctly within the pattern to achieve the desired internal features and ensure a smooth flow of molten aluminum.
  • Gating System: Design an appropriate gating system to allow aluminum to flow smoothly around the sand core, reducing the risk of defects.
  • Venting: Proper venting is essential to avoid gas entrapment during casting, which can cause defects like porosity.
  • Cooling Considerations: Factor in cooling channels or risers to control the cooling rate and minimize shrinkage-related issues.



Sure Cast has the capability to provide surface finishing through grinding, sand blasting and wheel blast/tumble blast.


Heat treatment improves and strengthens a part’s material properties. This process involves controlled heating (to extreme temperatures) and cooling to achieve a desired result such as hardening or softening aluminum.

We have an in-house T6 Heat Treatment process that we perform to customer specifications. We control the process to keep cost down while retaining part integrity and on-time delivery.

For further details on heat treating processes, please see our Articles on the subject here:

Introduction to Heat Treatment 

Below The Surface of Heat Treatment 




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Contact us today to find out how Sure Cast Aluminum Foundry can deliver your next project on time with exceptional value.