How Sand 3D Printing Is Changing Modern Casting Industries

Writen by
Dai Yan
Last update:
June 9, 2025

Sandcasting is an old way to make metal parts. It uses packed sand around a…

Sandcasting is an old way to make metal parts. It uses packed sand around a model to form a mold. But this method takes time and needs special tools.

Now, sand 3D printers are changing everything. These printers build sand molds one layer at a time. They don’t need patterns or molds made by hand. This makes the process faster and easier. 

Many industries use this new method. In cars, it helps make engine parts. In planes, it builds lighter parts with great detail. Sand 3D printing saves time, cuts waste, and makes complex shapes possible.

This guide will show you how it works—and why more companies are using it.

What Are Sand 3D Printers?

A sand 3D printer, also known as a binder jetting 3D printer for sand casting, is a type of 3D printing technology designed specifically for creating sand molds and cores used in metal casting processes. These printers are not meant for creating final parts or objects but rather for producing the molds and cores needed to cast metal parts with complex geometries.

Several industry leaders make these printers. voxeljet, ExOne, and Desktop Metal are well-known for their 3D printing systems. Each brand has its own machines for different part sizes, resolutions, and speeds.

The primary purpose of a sand 3D printer is to produce highly detailed and intricate molds and cores for casting applications. These molds and cores are used to define the shape of the metal part being cast. 

Sand 3D printing provides benefits like quicker prototyping, shorter production timelines, and the capability to create complex shapes that are difficult or expensive to make with conventional mold-making methods. It is widely applied in sectors such as automotive, aerospace, and foundries to manufacture detailed metal parts through casting.

Image Alt text: Sand 3D printer creating a detailed mold layer by layer using binder jetting technology.

How 3D Printing Is Transforming Sandcasting

Modern 3D printing technology   hjhhhhhew3 is giving traditional sandcasting a powerful upgrade. Here’s how it’s changing the process:

No More Patterns or Tooling

In the past, sandcasting needed wooden patterns and molds. These took time to build and were hard to change. With sand printing, a 3D model is all you need. The printer builds the mold directly from layers of sand. No extra tools required.

Faster Prototyping and Production

What once took days now takes hours. A 3D sand printer speeds up both prototyping and serial production. You can test new designs quickly and make small runs without delays.

More Design Freedom

Traditional molds limit your options. Making curved or hollow shapes is tough. 3D sand printing allows for complex undercuts and more creative forms. This gives engineers true geometric freedom when designing parts.

Less Waste, Lower Cost

Older methods often waste material. You carve from a block and throw out the rest. 3D printing builds only what you need. This reduces excess materials, lowers production cost, and makes for cost-effective casting.

Companies using sand 3D printers gain a strong competitive advantage. They work faster, spend less, and create better designs. It’s no surprise the foundry industry is turning to this smarter production method.

Jet 3D Printing Technology Explained

Jet 3D printing is the main method used in sand 3D printing. The full name for this method is binder jetting. It’s fast, accurate, and perfect for making molds.

Binder jetting builds shapes one layer at a time. A thin layer of sand is spread across a surface. Then, a print head sprays a liquid binder to hold the grains together. This process repeats to form the full shape.

Each spray of binder lands exactly where it’s needed. This lets the printer build very detailed molds. Even small changes in a 3D model show up clearly in the final part. That’s why it’s ideal for complex castings and fine designs.

3D printing systems that use binder jetting can handle big jobs. They work fast and print large molds without slowing down. Some machines, like voxeljet’s VX1000 3D, are built for high-volume casting work. They keep up with busy production centers.

Jet 3D printing is great for the foundry industry. It helps make sand cores, molds, and even tools. These parts can be used right away or stored for later use. It’s a flexible production process that supports both one-time and ongoing projects.

Materials & Binders Used in Sand 3D Printing

The choice of sand and binder matters a lot in sand printing. These materials affect strength, finish, and how easy it is to clean the mold later.

Types of Sand Used

The most common sand is silica sand. It’s easy to find and works well for many castings. For stronger parts, some printers use chromite sand or even ceramic. These types help when parts need to handle heat or heavy loads. Some molds use a mix, or combination of sand, to match special job needs.

Kinds of Binders

Binders hold the layers of sand together during printing. Common binder types include furan resin, phenolic, and inorganic systems. Furan binders are popular because they work with many metals. Inorganic binders are better for clean casting and produce fewer gases. Each type affects how strong the mold is and how much post-processing is needed.

How Materials Affect the Final Mold

Binder choice impacts the strength of the sand mold, how smooth the surface is, and the mold’s performance in high heat. It also changes how easy it is to remove the binder after casting. Better materials lead to high-quality molds with less cleanup.

Costs and Environmental Impact

Some binders cost more than others. Inorganic binders are cleaner but harder to handle. Using eco-friendly options can reduce emissions in the foundry industry. Companies now look for ways to lower production costs while keeping up with quality requirements.

Just be sure to ask about the type of metal, binder, and how they clean and finish the parts. You can also read our guide to surface finishes to better understand your options.

Applications Across Industries

Sand 3D printing is used in many fields. It helps companies make better parts faster and cheaper.

Automotive Industry

In car factories, sand 3D printers build molds for engine components and other metal parts. The process is fast and cost-effective. It helps make detailed parts for testing and small runs. Companies enjoy better results without waiting for new tools.

Aerospace Industry

Airplane makers use 3D printing technology to create lightweight parts. These parts reduce fuel use while staying strong. Complex castings are possible with fewer steps. This gives the aerospace industry more design freedom and faster changes.

Foundries and Tooling Shops

The foundry industry uses sand printers to create molds and sand cores for casting. These tools can be used right away, which saves time. It’s great for both custom work and serial production. The technology also supports smooth production across shifts. Companies use sand printing for both one-time jobs and serial production. This is useful for testing, repairs, or making many parts in a row.

There are many real-world examples. Some foundries use chromite sand molds for high-heat parts. Others use silica sand surfaces for smoother finishes. These cases show how sand printing works for a wide range of industrial applications.

Challenges and Limitations

Sand 3D printing has many benefits, but it also has a few challenges.

First, the equipment costs can be high. A good 3D printer for sand molds is not cheap. Small companies may find it hard to buy one.

Second, handling materials like furan resin or chromite sand needs care. These can be harmful if not used safely. Workers need proper safety tools and training.

Third, post-processing takes time. After printing, the molds may need cleaning, drying, or extra coating. Removing unused sand and leftover binder isn’t always easy.

Another issue is dimensional accuracy. Sometimes the printed part isn’t the exact size you wanted. This can happen due to binder spread or sand shifting during printing. So, you may need to test and adjust.

Also, storing and moving printed parts can be tricky. A printed sand mold can break if not handled gently. This adds risk during transport in big production centers.

Even with these limits, companies are solving problems fast. Better machines, smart software, and safer binder systems are making things easier over time.

Future Trends in Sand 3D Printing

Sand 3D printing is growing fast. New ideas are making it even better.

One big change is the use of sustainable binders. These binders are safer for workers and better for the planet. They reduce smells, smoke, and waste. Some printers now use inorganic binder systems that work well and stay clean.

Another trend is smarter machines. 3D printing systems are now being used with digital twins and simulation tools. This means you can test a mold on a computer before printing. It helps catch problems early and improves the manufacturing process.

Automation is also a big focus. Many companies now want fully automated production lines. This means less human work, fewer mistakes, and faster builds. It also helps in serial production by printing many molds quickly.

More production centers are using sand 3D printers. These machines are becoming a top choice for the foundry industry and the casting industry. They offer speed, cost-effective solutions, and economic advantages.

Need Help with Sand Casting or Machining?

If you’re trying to make metal parts faster or want to try new designs without a lot of delay, it might be time to look at better options. Old ways of casting take a lot of time and don’t always let you change designs easily.

Some companies, like Huasuma, help solve these problems. They do metal casting, steel forging, and CNC machining all in one place. That means they can help with many kinds of projects—from car parts to tools for building and mining.

Our company is located in the Tongshan High-Tech Development Zone of Xuzhou, Jiangsu Province. Founded in 2019, and occupies a land area of 30,000 square meters, with workshop space covering approximately 15,000 square meters.

The company holds multiple national patents, participates in developing industry standards, and exports to over 60 countries worldwide.

If you want to save time and make strong parts without extra steps, working with a company like this could really help. Just be sure to ask about the type of metal, binder, and how they clean and finish the parts before you decide.

Conclusion: Why Sand 3D Printing Is a Smart Move

Sand 3D printing is changing the way parts are made. It’s faster than old casting methods, creates less waste, and gives more freedom to design complex shapes. You don’t need wooden patterns or extra tools—just a 3D model and the right materials.

With strong sand types, smart binders, and fast machines, companies now get better results in less time. This helps industries like cars, planes, and tool-making stay ahead.

If you want to improve your casting process, now is a good time to try 3D sand printing. A company like Huasuma can help you get started with the right tools and support, so your next project is faster, cleaner, and ready to grow.

About Anya

Hi, I’m Anya, founder of Hanke Machining. With a 40-year family legacy, we specialize in CNC machining, casting, and forging. We deliver high-precision parts for global industries with strict quality standards. Let’s create lasting partnerships together.

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