Sand casting is a simple yet effective way to create metal parts. It involves pouring molten metal into a mold made of sand, letting it cool and solidify, then breaking the mold to reveal the finished part.
The Basic Process:
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Pattern Creation: A pattern, mirroring the desired metal part's shape, is created. This can be made from wood, metal, or plastic.
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Mold Making: Sand, often mixed with a binding agent, is packed around the pattern to create a cavity. The pattern is then removed, leaving the empty cavity.
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Melting the Metal: The chosen metal is melted in a furnace to a liquid state.
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Pouring: The molten metal is carefully poured into the sand mold's cavity.
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Cooling & Solidification: The molten metal cools and solidifies, taking the shape of the mold cavity.
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Mold Removal: Once cool, the sand mold is broken apart to remove the finished metal casting.
The sand mold is a temporary structure, disposable after the casting is complete. This makes sand casting a versatile and economical method for producing a wide range of metal parts, from simple shapes to more complex designs, as noted by sources such as MetalTek (https://www.metaltek.com/blog/what-is-sand-casting/) and Patriot Foundry (https://www.patriotfoundry.com/news/foundry-sand-casting-process-steps/). As stated in one source, sand casting "involves the pouring of molten metal into a cavity-shaped sand mould where it solidifies" ([Reference provided in prompt]). The simplicity of the process is highlighted by multiple sources, including Xometry (https://www.xometry.com/resources/casting/sand-casting/) which describes it as a "low-tech and relatively simple process".
