There are many steps to sand casting. Deciding on the object you want to cast is one. Determining the capabilities of a sand casting manufacturer are another. For if the incorrect one is used then you end up with final products that contain imperfections in design as well as stability. While design imperfections are definitely not what you want, lack of stability is what can damage your product and, possibly, the people using it. Therefore, research is required before you move your design to the production stage.
First, you want to work with a company that utilizes multiple sand casting equipment, particularly an aluminum foundry. Companies like Curto-Ligonier Foundries have both. The reason to use a foundry for aluminum is the metal is pliable. This means it’s easy to mold while also able to withstand high temperatures as it is cast. And, when done, the finished product has a sturdiness of other, more expensive metals.
Second, check out they generate prototypes, especially those with thin walls or complex designs. Do they do it with an air-set/no-bake foundry to provide as much detail as possible or do they immediately go to the foundry to generate a model? The foundry method may cause unnecessary flaws to appear, and that may cause your costs to go up.
Next, you need to determine how they certify your product. A cursory review of the mold and product cannot be done in this environment. Instead, they should have some form of chemical & physical lab, or at least outsource to one, which performs inspection for leaks and cracks of any sort. Even the sligtest imperfections should be disposed of in order to generate a better product.
Cost and customer service are other things to look at when searching for a sand casting manufacturer. Quotes should always be provided by the manufacturer ahead of time and factor in delays in casting due to construction of prototypes or needed extra materials. The quote process should be connected directly with customer service. Instead of denying issues with small imperfections of a final product, the company’s customer service department should work with you to resolve the issue to your complete satisfaction. No matter how long it takes or if it costs extra.