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Green Sand Casting

Green sandcasting is an efficient molding process that utilizes sand as the main molding material. This casting method is referred to as “green” since the sand is recyclable and there are no chemical additives in the sand, just clay, water and sand. The moisture content within the molds provides the binding structure for the sand. General Foundry’s proprietary blend of sand, water and clay is ideal for industry leading sand casting tolerances and surface finish. As a base for our green sand, we utilize extremely fine-grained olivine-based sand that is mined from Washington state. We can produce repeatable and aesthetically pleasing sand castings in as little as 2-4 weeks. Our full-scale turnkey operations include our own in-house pattern shop and machine shop, providing a best-in-class one stop shop customer experience.

Contact us for more information regarding our green sand economical casting processes and affordable clean metal casting solutions. You can also call us at 510-297-5040 and we will be happy to assist you with your questions.



Green Sand Casting Process

At General Foundry we specialize in producing sand castings with tight tolerances and stringent cosmetic surfaces. We produce a wide range of cosmetic, customer facing geometries; from handles to LCD screen shrouds, you will not believe it’s a casting on the device.. The processes for our green sand casting include the following elements:

  • Create shell or CO2 cores (if needed).
  • Pack sand against the positive pattern on both sides of the tool.
  • Remove mold halves from tool.
  • Insert any cores in mold halves (creating undercuts and/or hollow features)
  • Close mold halves on top of each other and pour metal.
  • Shake out (off) sand from the solid metal geometry.


Green Sand Casting Applications

The green sand casting process is an economical and efficient process that allows aluminum and zinc-aluminum to be poured  into a near net shape. At General Foundry, the components manufactured in our green sand casting process are utilized by the largest companies around the world. Some of the most prevalent industries we serve include the following:


Green Sand Casting Advantages

Due to its consistent, repeatable nature, green sand casting has been utilized as a casting resource for several hundred years. Some of the distinct advantages that green sand casting provides, includes the following:

  • Low cost production method
  • Can be utilized for low, medium and high production means
  • Affordable tooling costs
  • Prototypes can be manufactured quickly
  • Tooling accommodates design changes
  • Creates complex geometries


Contact General Foundry for your Green Sand Castings Today

Contact us for more information regarding our aluminum and zinc-aluminum green sand casting and prototyping capabilities. Or for a quicker and more accurate pricing request, send us your project specs, an image, or drawing of what you are looking to achieve, and we will get back to you with pricing details as quickly as possible.