Our Process
The Workhorse of Sand Casting
Green sand molding is the most widely used sand casting process and the backbone of Ironbound's production floor. Clay-bonded sand is mulled and conditioned in-house, then packed around a pattern by hand or with machine assistance to form the mold halves. Fast cycle times and low tooling cost make green sand the right choice for repeat production runs of bronze, aluminum, and iron castings.
All patterns are built and maintained in our in-house pattern shop. We store customer tooling and maintain it at no charge — on repeat orders, your pattern is ready to run without re-setup or re-qualification.
Best For
Repeat production runs of bronze and aluminum castings where cycle time and cost per piece are the primary drivers
Advantages
Why Green Sand?
High Production Rates
Green sand is the fastest molding process — ideal for repeat production runs where cost per casting and cycle time matter most.
Low Tooling Cost
Wood, resin, and match plate patterns made in our in-house shop at competitive tooling cost. Pattern storage for repeat customers at no charge.
Wide Alloy Compatibility
Green sand is suitable for bronze, aluminum, iron, and many copper-base alloys across the full weight range the process supports.
Weights from Ounces to 1,000 lbs
Green sand handles a broad weight range — from small fittings weighing a few ounces through large structural castings up to approximately 1,000 lbs.
Specifications
