Sand Casting Patterns

Collaborate with customers from start to finish

Use Solidworks and NX CAD design to see projects in 3D

Design from print or reverse engineer from sample

What we do

Innovative precision tooling for sand casting and a range of sand-casting processes

We design and engineer green sand and no-bake patterns for ferrous and non-ferrous metal castings.

Forte Tooling Technologies’ tooling expertise includes green-sand patterns for complex foundry and manufacturing applications, including vertically-or-horizontally-molded castings and both non-cored and highly-cored designs.

Our solutions include tooling for aluminum and iron castings for fire suppression, aftermarket automotive, marine, medical, agricultural, construction and industrial equipment manufacturers, as well as for other advanced manufacturers of complex, high-performance products.

About

Green Sand Casting

The term “green sand” is known principally because of the moisture content within the sand. The sand undergoes a “mulling” process in which various clay and chemical additives that act as binders are blended with the sand, which results in a compound suitable for the sand-molding process. This prepared sand mixture is then compressed around the pattern at specific pressures and temperatures to ensure it maintains its shape throughout the remainder of the casting process. The blended sand and binders are compacted around the pattern, taking on the shape of the desired casting.

Sometimes the design of the casting entails internal passageways being formed into the part. This is done by using sand cores, which are made of a similar sand mixture. The cores are strategically placed to form the necessary passageways in the casting. The two halves of the mold are subsequently closed, and metal is poured into the cavity where it’s left to solidify. After solidification, the sand is vibrated until it is released from the casting. The finishing process can then be completed by grinding, machining, plating, and/or painting.

Our capabilities

  • We design and build patterns for Air-Set, Jolt, or Automatic Molding Machines

  • We produce solidification simulations using “cutting edge” software

  • Patterns available to ship with risers and gating ready for production

  • We collaborate with our customers to ensure optimized production castability

  • 3D print prototype patterns can be produced for short runs, samples, or testing – all available within a few weeks
  • Patterns can be made of 3D printed ABS or machined from billet Aluminum – with aluminum or wood match plates
  • We can design and build machining, inspection, or saw fixtures for any castings

Green Sand Tooling Specifications

GREEN SAND CASTING PROCESSES

  • Green Sand
  • Green Sand with Sand Cores
  • Green Sand with Chills
  • Heat-Activated/Shell (also called hotbox and warmbox) core boxes
  • No-Bake Air Cores (Dump Box)

ALLOYS / METALS / HEAT TREAT

  • Aluminum
  • Iron
  • Grey Iron
  • Ductile Iron

GREEN SAND TOOLING ADVANTAGES

  • Excellent Flexibility in Choice of Molds and Patterns
  • Fast, Cost-Efficient Casting Process
  • Environmentally Friendly: Mold Aggregate can be Treated and Re-Used

About

No-Bake Sand Casting

In the no-bake process, sand is mixed with a chemical catalyst system, which is then molded around the cope and drag halves of the tooling. After a specified period of time (depending on mold size), the sand mixture hardens to form the mold halves, and the tooling is drawn. Additionally, a refractory coating may be applied to both mold halves before bringing them together to form one complete mold for pouring.

The pattern is removed leaving the mold cavity. Molten metal is then poured into the mold cavity. After the metal has solidified and cooled, the casting is separated from the sand mold. There is typically no mold release agent, and the mold is generally destroyed in the removal process. The finishing process can then be completed by grinding, machining, plating, and/or painting.

Sometimes the design of the casting entails internal passageways being formed into the part. This is done by using sand cores, which are made of a similar sand mixture in a no-bake air core process or in a shell (hot box/blown core process). The cores are strategically placed to form the necessary passageways in the casting.

No-bake molding, like green-sand molding, is known for its versatility. Virtually all metals can be cast via no-bake molding with component weights ranging from less than a pound to several hundred thousand pounds.

NO-BAKE SAND TOOLING SPECIFICATIONS

PROCESSES

  • No-Bake Mold Casting (Dump Box / Cope & Drag Boxes)
  • No-Bake Air Cores (Dump Box)
  • Heat-Activated/Shell (also called hotbox and warmbox) core boxes
  • We can accommodate patterns up to 50” x 60” in size

NO-BAKE SAND TOOLING ADVANTAGES

  • Very Accurate Molds/Cores
  • Dimensionally Accurate Castings
  • Castings with Tighter Tolerances
  • Smooth Surface Finish
  • Cost-Effective Casting Process

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