Sand Mold 3D Printng and Casting Service

From initial concept to final delivery, our comprehensive services cover every step of the product development process.

Get a free quote

Sand Mold 3D Printng & Casting

Sand Mold 3D printng , also known as 3D printed sand casting , is an advanced manufacturing technique that combines the precision and flexibility of 3D printing with traditional sand casting processes. This technology enables the creation of complex, High-precision molds directly from digital designs, eliminating the need for pattern-making or tooling. It is particularly advantageous for producing intricate geometries, reducing lead times, and lowering costs compared to conventional sand casting methods.

Get a free quote

Key Processes

Powdered Sand Material :

The primary material used in 3D printing sand molds is silica sand (SiO₂) , which is widely available and Cost-effective. Other materials like zircon sand , chromite sand , or ceramic beads may be used for specific applications requiring higher thermal stability or surface finish. These sands are typically mixed with a binder to create a moldable mixture.

Binder Jetting Technology :

Binder jetting is the most common 3D printing process used for sand molds. In this method:

  • A layer of sand powder is spread across a build platform.
  • A binder (usually a liquid polymer) is selectively deposited onto the sand using print heads, binding the particles together where needed.
  • The process is repeated layer by layer until the entire mold is formed.
  • After printing, the excess unbound sand acts as a support structure, which can be easily removed once the mold is complete.

Post-Processing :

Once the mold is printed, it undergoes curing to strengthen the binder and ensure the mold’s integrity. The mold is then prepared for casting by removing any loose sand and ensuring the mold cavity is clean.

Casting Process :

Molten metal (e.g., aluminum, steel, bronze) is poured into the 3D-printed sand mold. After cooling and solidification, the mold is broken away to reveal the final casting.

Materials We Work With

Overview: A lightweight, corrosion-resistant metal with excellent thermal conductivity. It’s widely used in industries like aerospace, automotive, and electronics.

Key Properties: Lightweight, strong, corrosion-resistant, easy to machine.

Applications: Aerospace components, automotive parts, and electronics housings. Aluminum is commonly used for CNC machining, and sheet metal fabrication due to its ease of machining and thermal properties.

Overview: Known for its strength, durability, and excellent corrosion resistance, stainless steel is versatile across many industries.

Applications: Industrial equipment, medical devices, and structural components. Stainless steel is ideal for CNC machining and sheet metal fabrication, particularly in environments requiring chemical resistance.

Brass

Overview: A copper-zinc alloy with excellent machinability and corrosion resistance, often used in precision parts.

Applications: Electrical connectors, plumbing components, and decorative parts. Brass is commonly machined and used in Low-volume production due to its ease of fabrication and good electrical conductivity.

Copper

Overview: Known for its superior electrical and thermal conductivity, copper is widely used in electrical and heat-exchange systems.

Applications: Electrical wiring, heat sinks, and plumbing components. Copper’s machinability and conductivity make it ideal for precision CNC machining.

 

Overview: A strong, lightweight, and corrosion-resistant metal used in high-performance applications.

Applications: Aerospace parts, medical implants, and automotive components. Titanium is often used for CNC machining and 3D printing, especially in industries where strength and low weight are critical.

Magnesium

Overview: One of the lightest structural metals, known for its excellent strength-to-weight ratio and machinability.

Applications: Aerospace and automotive components. Magnesium is ideal for CNC machining and sheet metal applications where reducing weight is essential.

Silicon carbide (SiC) is a high-performance ceramic known for its exceptional hardness, thermal conductivity, and resistance to wear and corrosion.

Specifications :

    • Particle Size: Typically 5–45 μm.
    • Density: ~3.2 g/cm³.
    • Hardness: Mohs hardness ~9.2.
    • Melting Point: ~2730°C.
    • Thermal Conductivity: High.
    • Electrical Conductivity: Semi-conductive.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for creating molds due to its high temperature resistance.
    • Ideal for casting components that require high-temperature performance, such as aerospace and automotive parts.

Zirconia (ZrO₂) is a versatile ceramic with excellent mechanical properties, including toughness and chemical stability.

Specifications :

    • Particle Size: Typically 1–10 μm.
    • Density: ~6.1 g/cm³.
    • Hardness: Mohs hardness ~8.2.
    • Melting Point: ~2715°C.
    • Excellent thermal stability and chemical resistance.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for making molds due to its ability to withstand high temperatures during casting.
    • Commonly used in dental prosthetics and orthopedic implants, but also suitable for industrial molds.

Alumina (Al₂O₃) is a widely used ceramic known for its high hardness, thermal stability, and chemical inertness.

Specifications :

    • Particle Size: Typically 1–10 μm.
    • Density: ~3.98 g/cm³.
    • Hardness: Mohs hardness ~9.
    • Melting Point: ~2072°C.
    • Excellent thermal and electrical insulation properties.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for creating molds, especially for high-temperature applications.
    • Suitable for casting components that require wear resistance and high-temperature stability.

Silicon dioxide (SiO₂), also known as silica, is a common ceramic material with excellent optical and thermal properties.

Specifications :

  • Particle Size: Typically 1–10 μm.
  • Density: ~2.2 g/cm³.
  • Hardness: Mohs hardness ~7.
  • Melting Point: ~1713°C.
  • Excellent optical transparency and chemical inertness.

Applications in Sand Casting/Binder Jet 3D Printing :

  • Used in binder jet 3D printing for creating molds, particularly for components requiring precision and transparency.
  • Useful in applications where low thermal expansion and chemical resistance are critical.

Tungsten is a dense metal with extremely high melting and boiling points, making it ideal for high-temperature applications.

Specifications :

  • Particle Size: Typically 1–10 μm.
  • Density: ~19.3 g/cm³.
  • Hardness: High.
  • Melting Point: ~3422°C.
  • Excellent thermal and electrical conductivity.

Applications in Sand Casting/Binder Jet 3D Printing :

  • While not typically used in sand casting or binder jet 3D printing for molds, tungsten can be used in binder jet 3D printing for direct part production, especially for heavy-duty components.
  • Often used in X-ray targets and radiation shielding.

Bronze is an alloy of copper and tin, known for its ductility, corrosion resistance, and low friction properties.

Specifications :

    • Composition: Copper (~90%) and Tin (~10%).
    • Particle Size: Typically 10–50 μm.
    • Density: ~8.8 g/cm³.
    • Hardness: Moderate.
    • Melting Point: ~950°C.
    • Good corrosion resistance and ductility.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for creating molds, especially for casting bronze or other metals.
    • Ideal for decorative and artistic applications, as well as components requiring good wear resistance and low friction.

Stainless steel is an alloy of iron, chromium, and other elements, providing excellent corrosion resistance and strength.

Specifications :

    • Common Grades: 316L, 310S, etc.
    • Particle Size: Typically 15–45 μm.
    • Density: ~7.9 g/cm³.
    • Hardness: Moderate to high.
    • Melting Point: ~1400°C.
    • Excellent corrosion resistance and biocompatibility.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for creating molds, especially for casting stainless steel parts.
    • Ideal for medical implants, marine equipment, and food processing machinery.

Superalloys are high-performance alloys designed for extreme environments, combining high strength, heat resistance, and corrosion resistance.

Specifications :

    • Common Types: Inconel, Nimonic, etc.
    • Particle Size: Typically 15–45 μm.
    • Density: ~8.0–8.5 g/cm³.
    • Hardness: High.
    • Melting Point: ~1300°C to 1400°C.
    • Excellent high-temperature strength and oxidation resistance.

Applications in Sand Casting/Binder Jet 3D Printing :

    • Used in binder jet 3D printing for creating molds, especially for casting superalloy parts.
    • Ideal for aerospace components, jet engine blades, and power generation systems.

Key Advantages of Sand Casting

Complex Geometries

Create parts with intricate internal passages, undercuts, and unique shapes difficult or impossible with 3D printing mold and sand casting.

Unparalleled Design Freedom

Easily creating complex structures and geometries and modify patterns and molds during the design process

Lower Tooling Costs

Sand molds (created from patterns) offer substantially lower initial tooling costs compared to permanent metal dies, accelerating prototype iterations and reducing risk.

Ideal for Small-to-medium Volumes

Perfect for functional prototypes, bridge tooling, pilot runs, and small-batch production where high-pressure die casting tooling is prohibitively expensive.

Why Us

At XM Group, we don’t just manufacture parts—we accelerate innovation. Our capabilities in CNC machining, 3D printing, sand casting and more allow us to use the best process for every single part of your project.  Here’s why industry leaders trust us as their End-to-end prototyping and precision manufacturing partner. 

End-to-end Capabilities

Simplify your supply chain. We combine sand casting, multi-axis CNC machining, industrial 3D printing under one roof. No juggling vendors. No compatibility gaps.

Fast Turnaround

Get functional prototypes and pre-production samples fast. Our integrated processes slash lead times while maintaining rigorous quality standards.

Flexible On-demand Production

Whether you need 1 prototype or 500 bridge-production units, our flexible capacity grows with your project—without sacrificing speed or precision.

Cost-effective

By eliminating the need for physical patterns and tooling, we significantly reduce upfront costs, making it economically viable to produce single prototypes or small batches of parts.

Ready for Manufacturing? Get a Free Quote & Expert Advice.

Have a CAD file or project specs? Our manufacturing engineers are ready to review your requirements and provide a fast, competitive quote for CNC machining, sand casting, 3D printing, binder jetting , or gear manufacturing.

Contact Us

Frequently Asked Questions.

We support all major CAD formats:
STEP, IGES, STL, SLDPRT, X_T, PARASOLID (and more).
Our engineers will review your design for manufacturability (DFM) and provide optimization suggestions before production begins.

We offer a wide range of materials for various manufacturing processes, including:

  • Metals (Aluminum, Steel, Titanium, etc.)
  • Plastics (ABS, Nylon, Polycarbonate, etc.)
  • Composites and specialized materials depending on the application. We also provide material consultation to help you select the most suitable materials for your project.

Absolutely. Our 5-axis CNC machining centers (±0.01mm) and industrial 3D printers excel at:

  • Intricate designs, thin walls, and internal features

  • Tolerances down to ±0.025mm for critical dimensions

  • Challenging materials (e.g., Inconel, PEEK, tool steels)

Absolutely! We offer a wide range of surface finishes and post-processing options to enhance both the appearance and functionality of your parts. Whether you need polishing, anodizing, painting, or another specific finish, we can accommodate your requirements.

Lead times vary depending on the service and project complexity. Rapid prototyping can typically be completed within a few days, while more complex manufacturing projects such as Low-volume production or tooling may take longer. Once we receive your project specifications, we’ll provide a detailed timeline.

Upload Your CAD & Get an Instant Quote

Partner with XM Group Smart Tech and experience the power of integrated rapid prototyping and manufacturing solutions. Whether it’s a concept model or a functional prototype, we offer a wide range of materials and technologies to bring your vision to life. From DFM feedback to Low-volume production, we simplify your product development journey.

en_USEN
de_DEDE ru_RURU en_USEN
Scroll to Top