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Custom Sand Castings
From simple to complex metal parts, sand casting is a versatile casting process. Due to this versatility, custom sand cast parts can be manufactured in a wide variety of shapes and sizes, most metal alloys and small to large quantities. As a custom sand-casting supplier, Deeco Metals provides high-quality machined castings. Our state-of-the-art foundry, machining and surface finishing equipment ensures the best quality parts. We are very reliable and offer stocking programs in our SC warehouse. Make Deeco Metals your best choice for custom sand cast parts for all commercial industries as well as all architectural applications.
We use the sand casting process to produce a wide range of parts in many different metals. We supply as-cast parts but prefer to supply machined castings, as this helps us find defects during the machining process, before shipping to you.
We provide full project consultation to help you:
- Choose the best method of manufacturing your parts
- Suggest the material best suited to your products
- Refine your designs to match the manufacturing method chosen
- Save on costs
Discuss your sand casting needs with us today. Deeco Metals’ experience and commitment to quality, allow us to offer you the best parts for your requirements. Regardless of industry or application needs, we have a technical support team ready to help with any questions on your projects.
Advantages of Sand Casting
Sand castings impose few restrictions on product shape
The only significant exceptions are the draft angles that are always needed on flat surfaces oriented perpendicular to the parting line. With good patterns and tooling, the proper choice of molding sands and careful foundry practice, surprisingly intricate details can be reproduced in this manufacturing process with a variety of metal alloys.
Dimensional control and consistency
Dimensional control and consistency in sand castings ranges from about ±0.030 to ±0.125” (± 0.8 to 3.2 mm) depending on the size and design of the parts. Within this tolerance range, the more generous tolerances apply across the parting line.
Surface finish ranges between approximately 300 and 500 gin (7.7 - 12.9 gm) rms
Various surface finishes on sand castings can be achieved and they are: machine finish, shot blast, painted (hand, spray and dipped), powder coated, plated (chrome, tin and others), acid etching, anodizing, galvanizing and various other unique polyamide durable coatings such as Rilsan.
Sand castings are relatively inexpensive compared to other manufacturing processes
The process is quite simple and most any metals can be used. Parts can be supplied as is or completely machined and coated.
Sand castings are acceptably precise and above all, highly versatile
This process can be applied to simple shapes as well as castings of considerable complexity, and it can be used with all metals such as aluminum, cast iron, ductile iron, copper alloys (brass, coppers and bronzes), steel alloys, stainless alloys, and other complex metals.
Sand castings also lend itself to low volume production as well as high volumes
Contact Deeco Metals today to request a quote or to learn more about how Sand Casting can work for your project.
Sand Cast Parts
Sand casting molds also know as patterns are made of wood or aluminum and can be changed to accommodate any small changes in designs so small changes are very inexpensive. Sand casting can produce a wide range of different parts in weights ranging from less than an ounce to thousands of pounds. Deeco Metals excels at casting parts with simple to complex geometries for industries across the industrial and architectural spectrums. Some examples of the parts we produce are listed below.
Mechanical & Architectural Parts
Small to Medium Size Parts
- Gearboxes and housings
- All types of valves and strainer parts, valve bodies & housings
- Pump parts, bodies & housings
- Water fittings
- Flywheels & handwheels
- Architectural parts
- Fence post parts
- Marine windows (portholes) and doors, corrosive resistant fittings as well as anchors
- Yachts fittings and parts
- Shipbuilding parts
- and much more
- Equipment housings
- Large parts for road trailers
- Large pipe fittings: elbows, Ts, connectors, etc.
- Wind power fittings & housings
- Off-road equipment parts
- Heavy machine bases and tables
- and much more
Custom Sand Casting at Deeco Metals
Our foundries can produce custom patterns in wood or aluminum to use in the sand casting process to produce any new or legacy metal parts you require. No matter what industry you are in, Deeco can supply the metal parts you need! Contact us to request a quote or to schedule a consultation.REQUEST A QUOTE TODAY!
What is Sand Casting?
The sand casting process requires a wooden or metal pattern, a sand core box, a furnace to melt the raw metal, grinders for fettling and removing flash, finishing equipment to improve the surface of the casting, various machines to finish the parts, as needed.
Molten metal is poured into the sand cast mold and, after it has cooled, the sand is removed manually or automatic shakers. The metal part is then fettled (by grinding) to clean up the excess metal flash (parting line), risers, gates, and spruces and then cut off and then a surface-treated via shot blasting or a similar process is used to get parts ready for finish machining.
Metal Alloys are obtained in the form of specked out ingots or scrap. These are then melted and alloyed to the metal specifications required.
- The first step in the process is placing the wood or metal pattern, which replicates your metal part design, into a metal or wooden sand mold box.
- Next, the box is filled with sand, which is compressed firmly around the mold/pattern to form the part cavity. Generally, a resin is added to the sand ahead of molding, so it cures solidly around the pattern.
- The mold is then carefully removed from the sand leaving behind a cavity.
- Molds are typically made in two halves: an upper portion (the cope) and a lower portion (the drag). These two halves are placed together to form the complete cavity, ready for metal to be added.
- Molten metal is then poured into a spruce or runner, which is the hole in the sand to fill up the cavity.
- The boundary between cope and drag is known as the parting line and this is ground off.
- A riser (vent hole) that allows gas to escape as molten metal fills the cavity is also needed and excessive metal fills this as well. The riser can be part of the pattern or it can be added manually after the two sand mold halves are placed together.
- Metal is melted in an electric induction or gas-fired furnace to the required temperature and is ladled or poured into the spruce that fills the mold cavity that was formed by the pattern. Gasses and air escape through the riser and once this hole is filled with molten metal, it indicates that the mold cavity has been filled completely.
- Once the metal has had time to solidify and cool, the sand is removed.
- The metal runners, risers, gates are still part of the casting and these are cut off with a cutting wheel or removed by a saw. The flash is also removed by grinding. This process is called fettling.
- The castings are then cleaned by various methods (shot blast, etc.) to remove any residual sand and to blend any imperfections or parting lines.
- The casting is now ready for machining.
How Common is Sand Casting?
Sand casting parts currently account for about 75% of U.S. foundry production of copper alloy, gray and ductile iron, stainless steel, and aluminum.