SAND Casting Services
Redstone Manufacturing offers sand casting services for aluminum, steel, iron, brass, and other materials and is equipped to handle specialty parts to large volume runs. Sand casting is a rapid, cost-effective solution for manufacturing metal parts.
OUR PORTFOLIO OF
SAND CASTING COMPANIES
Finding a reliable sand casting company in the United States doesn’t need to be difficult or expensive. Redstone Manufacturing has sand casting facilities in China, Mexico, India, Taiwan, and Brazil. We help you secure the best rates and lead time for your sand casting job. Our headquarters in the United States means we are dedicated to quality and meet ISO9001 standards. We help companies reduce the risk of working with foreign manufacturers, while lowering costs.
What Products are Made from Sand Casting?
Compared with other casting methods, sand casting is ideal for large-part production. This method offers engineers a variety of metal alloy options and part size options at an affordable manufacturing price. Additionally, sand casting has a low setup cost and is inexpensive to make mold modifications. This is the preferred casting method of the aerospace industry, and others such as construction, automotive, manufacturing, and even marine industries use sand casting.
Common Products &
Use Cases of Sand Casting
- Engine blocks
- Pipes
- Nuts
- Landing gear
- Pulleys
- Cylinder heads
- Aerospace components
- Machine tool bases
Sand Casting COMPARED TO INVESTMENT CASTING
Both methods have been around for centuries, but the final product will dictate which option is best to use.
Sand Casting Services
- A range of different parts or several of the same part may share a mold.
- New molds are easy to remake.
- Higher casting weight limit.
- Greater ease of changing design.
- Difficult to cast parts with internal voids.
Investment Casting Services
- Ceramic mold (initial investment) is destroyed to get parts.
- Better equipped to make small, intricate parts.
- More complex and labor-intensive.
- Hundreds of small parts can be cast at once.
- Excellent surface finish.
- Greater design freedom.
Sand Casting Services in USA
Redstone Manufacturing provides high-quality sand casting services for industries requiring durable, cost-effective, and versatile metal components. With our ISO-certified foundries and decades of expertise, we produce precision-engineered castings in aluminum, iron, steel, brass, and other alloys. Whether you need low-volume prototypes or large-scale production runs, our sand casting service delivers consistent results tailored to your technical requirements.
The Sand Casting Process
Sand casting is one of the oldest and most adaptable metalworking processes. It involves creating a mold by compacting specially prepared sand around a pattern of the desired part. Once the mold cavity is formed, molten metal is poured into it and allowed to solidify. After cooling, the sand mold is broken away to reveal the cast component.
The process supports complex shapes, large dimensions, and thick or thin-walled designs. It is especially suitable for heavy-duty components and low-to-medium production volumes where tooling flexibility is essential.
Redstone’s sand casting services use advanced molding techniques, high-quality sand mixtures, and precise metal pouring controls to ensure dimensional accuracy, excellent mechanical properties, and minimal defects.
Why Choose Redstone Manufacturing
When selecting a sand casting service provider, Redstone stands out due to its unmatched capabilities and engineering expertise:
- Foundry Manufacturer – Multiple international facilities ensure stable supply chains and competitive pricing.
- Full Material Range – Aluminum, gray iron, ductile iron, steel, brass, bronze, copper alloys, and custom material options.
- Engineering Support – We optimize gate design, risers, draft angles, and pattern construction to improve casting quality and reduce costs.
- Advanced Tooling & Patterns – CNC-machined patterns, 3D-printed patterns, and high-precision tooling for fast turnaround.
- Strict Quality Control – Dimensional checks, chemical analysis, hardness testing, and NDT methods such as X-ray and ultrasonic inspection.
- End-to-End Manufacturing – From design consultation and prototype production to finishing, machining, and final delivery.
Redstone Manufacturing offers the expertise, reliability, and scale needed to deliver consistent and cost-efficient sand casting services for any industry.
How to Order Sand Casting Services
Our ordering process is designed to be simple, transparent, and efficient:
- Send Your Drawings
Provide your 3D model or technical drawing. Our engineers analyze the design for manufacturability. - Get a Detailed Quote
We deliver a complete cost breakdown including tooling, materials, casting, machining, and lead times. - Pattern Creation & Tooling Setup
Depending on the project, we produce CNC or 3D-printed patterns, core boxes, and molding tools. - Casting Production
Molten metal is poured into the sand molds under controlled conditions to achieve consistent quality. - Cleaning & Finishing
After shakeout, the casting is cleaned, deburred, heat-treated if required, and finished according to the specification. - Inspection & Delivery
Each part undergoes quality checks before being securely packaged and shipped worldwide.
Ordering sand casting services from Redstone ensures predictable lead times, excellent quality, and full visibility at every stage.
Sand Casting Subtypes
Redstone offers several variations of sand casting services to meet diverse manufacturing requirements:
Green Sand Casting
Uses a mixture of silica sand, clay, and moisture. Ideal for high-volume, cost-effective production of general-purpose castings.
Resin Sand Casting / No-Bake Casting
Sand is bonded with resin, creating stronger molds for higher accuracy and improved surface quality. Suitable for larger or more complex parts.
Shell Mold Casting
A resin-coated sand shell forms thin, rigid molds with excellent precision and surface finish. Recommended for detailed and thin-walled components.
Lost Foam Casting
A foam pattern evaporates when molten metal is poured, allowing extremely intricate and accurate shapes.
Each casting subtype provides specific advantages depending on material, tolerance requirements, and production volume.
Product Finishes
To ensure that every part meets your exact specifications and performance requirements, we offer a full range of finishing options:
- Standard As-Cast Finish
- Shot Blasting / Sand Blasting
- Grinding & Deburring
- CNC Machining
- Heat Treatment (normalizing, quenching, tempering)
- Powder Coating
- Painting
- Anodizing (for aluminum)
- Electroplating
These finishes enhance durability, corrosion resistance, appearance, and dimensional accuracy.
Applications and Industries
Our sand casting services are used to produce components for a wide range of industries, including:
- Automotive: engine blocks, manifolds, brackets, housings
- Heavy Machinery: gearboxes, pump bodies, industrial frames
- Aerospace: durable structural components and prototypes
- Oil & Gas: valves, flanges, and pressure-resistant parts
- Construction: supports, connectors, and custom metal fittings
- Agriculture: housings, wheels, high-strength mechanical parts
Redstone manufactures both simple and highly complex castings, ensuring reliability and long service life in demanding environments.
Advantages of Sand Casting
Choosing sand casting services offers significant benefits:
- Design Flexibility: Suitable for very large parts, intricate shapes, and custom geometries.
- Material Versatility: Works with almost any metal alloy.
- Low Tooling Costs: More affordable pattern-making compared to die casting.
- Cost-Effective for Small & Large Parts: Ideal for large components and medium-to-low production volumes.
- Fast Prototyping: 3D-printed patterns speed up early-stage development.
- Strong Mechanical Properties: Excellent durability and performance under heavy loads.
Redstone ensures that every sand-cast component meets the highest standards of strength, accuracy, and efficiency.
FAQ's ABOUT OUR Sand CASTING SERVICES
Sand casting is widely used because of its ability to cast metals that have high melting temperatures, low cost, and flexible production options. Unlike other casting options, sand casting is an affordable way to cast larger parts without expensive machining costs.
Both sand casting and investing casting have been around for ages. Investment casting is typically used when an engineer or designer needs smaller parts with intricate details. Sand casting allows for the production or larger, heavier parts and at a lower cost. Investment casting tends to be more labor-intensive since mold creation requires more steps prior to casting and additional machining steps after the metal has cooled.
Out of the most widely used metal casting methods, sand casting is the least expensive for smaller batch runs. It is also a cost-effective model for large part production
The three types of sand used for sand casting are Green Sand, Silica Sand, and Resin sand. Sand casting with green sand is fast and inexpensive because sand is able to be reused for later castings. Its soft, reusable properties also mean the mold can shift or collapse during the casting process. Silica sand is a good choice because it can quickly turn from liquid to solid. Casting with silica requires more time because of additional steps to break down the mold after the metal has cooled. Resin sand allows for a smooth surface mold, which translates to fewer defective parts. This sand also comes with slower casting time and higher cost.
SAND CASTING MATERIALS
Redstone’s Manufacturing’s sand casting services can utilize seven different metal material types – grey iron, ductile iron, stainless steel, alloy steel, carbon steel, aluminum, and copper.
Grey Iron
Sand Casting
Grey iron gets its name from the color of the fracture. It’s commonly used for sand casting because of its good machinability and nominal cost.
Ductile Iron
Sand Casting
Ductile iron sand castings are strong and well known for its impact and fatigue resistance. Its round graphite inclusions add its ductility and inhibit cracks throughout a part’s life.
Stainless Steel
Sand Casting
Stainless steel is a popular option for industries that need parts that are both durable and stand up to corrosion. Under most applications, this metal has the ability to retain its qualities without additional plating or coating.
Alloy Steel
Sand Casting
Low-alloy steel contains varying amounts of different elements that enhance the qualities needed for each part’s intended use. Alloy steels are tough and wear-resistant and are able to withstand high temperatures making it an excellent choice for industrial applications.
Carbon Steel
Sand Casting
Carbon steel gains its strength from added carbon and is well known for its durability. It is incredibly corrosion-resistant, and these parts have a long shelf life when properly protected and maintained.
Aluminum
Sand Casting
Aluminum is among the most popular metals used for casting because of its unique ability to create both strong and lightweight parts. Depending on its alloy composition, aluminum is a reasonably priced option compared to other metals with similar properties.
BRASS
Sand Casting
Brass sand cast parts are commonly used in the construction industry because of its attractive finishing options and, more importantly, its resistance to corrosion and rust.
Our SAND casting facilities Serve:
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Changed from Brochure to Newsletter on 8/12/24