1. ACTech
  2. Capabilities
  3. Metal Casting
  4. Sand Casting

Sand casting

Faster, more accurate, more complex – we are distinctly better than the rest with sand casting. State-of-the-art technologies, freely combinable mold production processes and a breadth of experience gained from more than 35,000 different constructions guarantee that you can unequivocally 'all in' with us. Highly complex prototypes and small batches with a commitment to tight deadlines are our specialty.

  • Production of highly complex castings in various sizes 

  • Combinable mold production processes for maximum flexibility 

  • Patternless and pattern-based mold production for prototypes and small batches 

Sand casting at ACTech:
rapid prototyping with high expertise

The sand casting process enables the production of highly complex parts with sophisticated geometries, low wall thicknesses and high surface quality. The prerequisites for this are established during mold production. Where other suppliers offer either patternless or pattern-based mold production, we use both options – and thus leverage maximum quality and speed from sand casting. Depending on the casting construction, we can also combine the individual mold production processes. This means that 'all in' with sand casting at ACTech gives you not 'either or' but top performance as part of a total package.

 

Know-how and a sure instinct are needed to produce batch-comparable parts in sand casting. This is why, with us, all process steps are performed by highly qualified specialists. In addition, we use a variety of innovative and proven technologies plus diverse testing methods to guarantee maximum quality at all process levels. Do you need even more control? You can contact your personal project management team at any time during production. You also have a dedicated contact person who keeps you up to date on all information concerning your component.

  • Manufactory production 
    Unique handwork instead of automated production 

  • Experience 
    Expertise from the production of over 230,000 prototypes in metal 

  • From a single source
    Mold and core production, mold assembly, casting and finishing under one roof 

Sand casting mold production

 

3D printing

3D printing is our latest technology for producing molds in sand casting: In this additive process, all required mold segments and cores are printed from different molding materials. Large platforms make it possible to produce several cores and mold segments simultaneously. Depending on the casting construction, we offer two variants of this mold production process: 3D phenolic resin printing for particularly delicate and high-strength cores and mold segments, and 3D furan resin printing with a suitable build platform for the rapid production of large mold segments.

  • Patternless method 
    Mold segments and cores are printed 

  • 3D phenolic resin printing (cold phenolic resin process) 
    Sand casting mold production without post hardening 
    Constructed space size: 800 x 500 x 400 mm 

  • 3D furan resin printing 
    Rapid, cost-effective mold production process thanks to larger platform 
    Constructed space size: 1,800 x 1,000 x 700 mm

Direct mold milling (DMM®)

Whether commercial vehicles, construction machinery, maritime applications or railroad technology – sometimes the job is a bit bigger. ACTech has developed direct mold milling (DMM®) for particularly large mold segments. With specialized tools, we mill the mold for your prototype directly into the sand – and thus save much time during mold production for sand casting. To enable the production of very complex structures, we combine direct mold milling with our other mold production processes.
 

  • Patternless method 
    Mold segments milled directly into the sand 

  • Large dimensions of mold segments 
    Constructed space size: 2,400 x 1,400 x 800 mm 
     

  • Rapid single part production 
    Combination with other mold production processes for even more flexibility
     

Mold production with foundry pattern making

Producing a separate casting pattern is particularly advisable for the production of very small / small batches with more than 100 castings. This is made of robust plastic so that, depending on the type of plastic used, molding can be performed up to 250 times. We thus combine pattern-based sand casting and rapid prototyping for projects that go beyond classic prototype production.

  • Pattern-based method 
    Reusable plastic pattern ideal for very small and small batches 

  • Efficient combinations 
    Pattern-based and patternless processes in one mold for time and cost savings  

  • Flexible quantities
    Enables up to 250 impressions from one pattern 

Mold assembly for sand casting

Absolute precision is required when assembling the mold. As a consequence, we not only rely on our extensive expertise but also use state-of-the-art optical measuring technology during mold assembly. We can thus guarantee above-average accuracy when assembling the mold segments and cores – in turn achieving our batch production-comparable low tolerances.

  • High surface finish 
    Smooth surfaces due to various methods of applying the coating 

  • Precise fit guaranteed 
    Use of optical measurement technology for minimum tolerances 

  • Foundry accessories included 
    Installation of chills, filters, heating elements or feeders for directional solidification

The foundry – from mold to finished casting

Once the mold for sand casting has been completed, our foundry specialists then roll up their sleeves: They melt standard, special or customer alloys in several furnaces to cast your component. Whether aluminum, iron or steel – we can process everything. And that's not all: We also cast function elements from other materials on customer request.

  • Alloys 
    Aluminum, cast iron, steel, nickel and copper alloys 

  • Technologies 
    Patented thermal processes and cooling technologies for maximum quality 

  • Speed 
    Parallel casting of ferrous and non-ferrous materials

Unpacking of castings – step by step towards success

Unpacking the castings is all about the right technique: We perform this task in several sub-steps with machine support in order to completely detach the mold from the casting without damaging it. We rely on much manual work for a particularly gentle process, but also use, among other options, a shock wave system for core removal of the castings with complex internal geometry and core breakdown annealing.

  • Gentle procedure 
    Multi-part unpacking process for damage-free parts 

  • Machine support 
    Shock wave system for core removal of castings 

  • Preparation for the test 
    Castings are prepared for testing and post-machining 

Sand casting with lowest possible tolerances

In the area of sand casting we work according to the DIN EN ISO 8062 standard for geometric product specifications. The most important thing is to guarantee lowest possible tolerances, and we are quite a bit ahead of the competition in this respect: Through the combined use of innovative mold production processes, we consistently realize above-average results for standardized casting tolerances, thus proving advantageous for your prototype production and/or small batch production. Put another way, our tolerances in sand cast prototyping are so close to the specifications for batch casting that you can always rely on us for prototypes comparable to batch production.

FAQ

How often can the mold segments be used?

How often can the mold segments be used?

Sand casting is based on 'lost molds' which are destroyed during or after the casting process. All mold segments can therefore only be used once. This applies to both patternless and pattern-based mold production processes.

How do you know which core belongs to which mold?

How do you know which core belongs to which mold?

We assign an individual identification code to your project. Each document, each mold segment and each core is given this code, making the assignment of every part, no matter how small, unequivocally possible.

Is it possible to combine the different technologies in one mold?

Is it possible to combine the different technologies in one mold?

Our sand casting technologies are 100% compatible and can be freely combined. This means we offer you more than our competitors in terms of prototype casting, because where individual mold production processes are limited we realize even highly complex and completely new constructions through combined technologies.

How can ACTech guarantee tight casting tolerances?

How can ACTech guarantee tight casting tolerances?

We use an optical scanner for assembly of the molds. This intuitive system is thus used to verify on a screen whether the scanned mold matches the 3D data of the part. This helps us provide fast, reliable service whilst ensuring the tight casting tolerances specified by you.