Sand casting process
For prototypes comparable
to batch production
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
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.
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.
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.
Laser sintering was the first mold production process we began with at ACTech over 25 years ago. To this day the technology is used for special challenges – e.g. when we need maximum core stability for particularly fragile structures.
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.
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.
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.
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.
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.
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?
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.