Cost-Effective Custom Sand Casting Services

The oldest and most versatile method for producing aluminum castings is sand casting. Le Sueur offers custom green sand casting that is suitable for use in a wide selection of markets, such as transportation, medical, or agriculture. Sand casting tooling is a low cost and efficient way to cast aluminum products that meet the demands of your application. Sand casting with Le Sueur is relatively easy to modify as the demands of your project change.

Automatic Green Sand Casting for Dimensionally Complex Applications

Le Sueur Incorporated has (3) Automatic Casting Lines and (2) Cope and Drag Casting Lines for aluminum green sand molding. LSI specializes in dimensionally complex and pressure tight applications. Aluminum alloys poured include 319, 355, 356 & A356.

We also offer complete in-house core making, heat treating, precision casting machining, finishing, and assembly services. Our casting experts provide design engineering assistance and offer prototyping services in the early design and manufacturing stages.

Our in-house Core Making consists of Isocure and Shell Core processes to deliver quality results.

Other technology utilized within our sand casting processes include:

Common Sand Casting Applications

Sand casting manufacturing can be used for a wide variety of industries and applications. Common applications include:

  • Air Cylinders
  • Aluminum Housings
  • Cooling Fins
  • Covers
  • Electrical Boxes
  • Electrical Transmission Equipment
  • Fans Blades & Hubs
  • Gear Boxes
  • Gear Cases
  • Hubs
  • Hydraulic Cylinders
  • Impellors
  • Manifolds
  • Marine Components
  • Oil Pans
  • Pressure Housings
  • Pump Components
  • Suspension Components
  • Transmission Channel Plates
  • Valve Bodies
  • Valve Housings
  • Wind Generation Equipment

Sand Casting Processes and Green Sand

The sand casting process starts with two patterns:

  • One pattern is used to form the top mold half called the “Cope”
  • The other pattern is used to form the lower mold half called the “Drag”

A fine sand mixture called Green Sand is then packed tightly around the patterns.

When the patterns are removed and the two mold halves are assembled, a mold is formed into which the aluminum is poured. Sand cores can also be inserted into the mold to form hollow passageways or to cast intricate geometry that cannot be formed by the sand casting patterns.

As compared to die casting and permanent mold casting, sand casting is a slower casting process but often more economical for lower production requirements due to the low upfront investment in tooling. Sand castings have a high degree of structural integrity. 

What is Green Sand?

The term "Green Sand" is used to describe the sand used to form the sand molds. The sand is in a "green" or uncured/wet state. Green Sand is actually black in color and is a compilation of materials including silica, bentonite (clay) and water. The Green Sand is reclaimed and reused.

Start Your Sand Casting Project Today

Le Sueur Incorporated specializes in green sand casting and other aluminum casting methods to produce dimensionally complex, pressure tight aluminum castings. Our other services include plastic injection molding and complete in-house precision machining, finishing and assembly. Please contact us to learn more about our capabilities and discuss your sand casting project!