Aluminum Sand Casting

For more than thirty years, Sure Cast has produced top-quality sand castings for a diverse and comprehensive range of industries. We work with our customers as partners to assist them in achieving their metal manufacturing goals and objectives.

We are committed to providing quality castings and on-time delivery along with exceptional value, making sure you gain a competitive advantage in your specific market.

We collaborate with our customers from Design to Production Launch

Capable of complex part geometries, with flask sizes from 16" x 20" up to 36" x 36"

Offer finished products with full Heat-treating, Precision-Machining, and Specialty Coating services

What we do

Whether low or high volume, simple or complex part geometries, we offer fully finished castings, bolt-on ready delivered to your production floor


Green 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

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.


  • Flask sizes available range from 12″ x 12″ to 36″ x 36″



Sure Cast has the capability to make all cores to meet our customers’ needs. We use a variety of core processes, including shell and no bake.



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


Heat Treatment

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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