Sand Casting FAQ

AA 356 T6 and A356 are very similar in properties with AA A356.0 being a higher purity alloy. In the heat-treated T6 condition, AA A356.0 is stronger, more elastic, and harder than AA 356.0. Mechanical properties for the two alloys can be found on our 356 Aluminum Sand Casting page.

• Sand castings require a low capital investment in tooling. A typical sand-cast pattern costs from $500 to $7,500 depending on the complexity of the part. A die-cast tool will cost from $7.500 on the low end up to $75,000 on the high end.
• Large components can be produced as well as complex shapes with coring.
• Low to mid-volume production runs are typical.

We pour a variety of lead-free alloys with the most common being CDA C89833 because it complies with the Safe Water Drinking Act and U.S.A Environmental Act.

LB Foundry specializes in non-ferrous sand castings and pours aluminum alloys (319, 356, A356, and 535 / Almag 35), brass alloys (yellow brass, red brass C83600, and lead-free red brass), and bronze alloys (silicon bronze, aluminum bronze, and manganese bronze).

Both are Al-Si-Mg casting alloys but differ in iron content. 356.0 permits up to 0.6% iron and is a cost-effective general-purpose alloy. A356.0 limits iron to 0.2% or less, significantly improving ductility, elongation, and fatigue resistance. A356 is commonly specified in T6 temper for structural and safety-critical applications.

Two primary methods: Green Sand Molding (sand blended with clay and water, cost-effective, ideal for high-volume production) and Air-Set (No-Bake) Molding (chemical binder, no heat, tighter dimensional accuracy and superior surface finish for larger or more complex castings).

Yes. LB Foundry operates an in-house machine shop performing milling, drilling, turning, tapping, and other CNC and manual machining operations directly on finished castings, simplifying procurement and shortening lead time.

Yes. 3D printed patterns allow customers to produce prototype castings at low tooling cost before committing to permanent production tooling — ideal for design validation, fit checks, or accelerated pre-production schedules.

Yes. LB Foundry provides pattern tooling and design assistance, reviewing part drawings for castability and recommending modifications that improve yields, reduce scrap, and lower total cost per casting. Engaging the team early — even at the concept stage — is the most effective approach before permanent tooling is built.

Castings are monolithic with no weld seams, deliver consistent part-to-part quality, allow design freedom for complex internal features, carry lower labor cost at volume once tooling is amortized, and reduce part count by consolidating multiple components into a single piece.

Cost is driven by pattern and tooling investment (one-time, ranging from a few hundred to several thousand dollars), part weight and alloy, order volume, molding process, and secondary operations such as heat treatment, machining, and pressure testing, which are quoted separately.

LB Foundry maintains a documented Quality Management System (QMS) covering the entire casting workflow from incoming material through final inspection. Capabilities include dimensional verification, visual inspection for surface defects, and metallurgical testing of alloy chemistry.