Airset Sand
Casting

Our air set
sand casting process allows us to produce all manner of castings from cleaning machines to brewery beer fonts.

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Air-Set Sand Casting Method

For smaller batch sizes and prototype castings, we typically use the air-set sand casting method. DAC offers sand castings in Aluminium, Brass, Bronze, and zinc.

Induction Melting Facility

Our Induction melting facility is a game-changer for copper-based alloys like gunmetal. It ensures that the metal is melted at the fastest rate possible, which is crucial for maintaining the best metal quality. This process effectively alleviates gas or porosity in the finished castings, giving you the assurance of high-quality materials in your castings.

Modern Pattern Equipment

While we still cater to small batches from traditional wooden patterns, our focus is on modernity. Most of our pattern equipment is produced from CAD models and manufactured on CNC machines. This not only ensures increased pattern life, better surface finish, and speed of production but also reassures you of our commitment to using advanced technology.

Sustainable Sand Reclamation

While we still cater to small batches from traditional wooden patterns, our focus is on modernity. Most of our pattern equipment is produced from CAD models and manufactured on CNC machines. This not only ensures increased pattern life, better surface finish, and speed of production but also reassures you of our commitment to using advanced technology.

Perfectly form sand castings

Watch our short video on YouTube on how the sand casting process 

Complicated sand castings
A person filling up the mould with sand to build the sand castings
Close up of sand castings
Another closeup of circular designs of sand castings

View our latest sand casting projects in our gallery

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    Do you have a project in mind you need some help with? Please don’t hesitate to contact us via our contact form or call 01902 324646.

    Chris Hickman

    Foundry Manager

    Quality

    Quality is
    at the forefront
    of customer requirements, this is why DAC have made it our mission to strive for excellence in this field.

    ISO 9001

    Continual internal audits along with ISO 9001 audits ensure all of our quality procedures are monitored to the highest standard always looking for improvement.

    Method sheets

    Method sheets are introduced at the beginning of the casting process to ensure continuity in the casting run, along with periodic visual checks as the casting passes through each stage in the foundry.

    Fully Documented

    Material batches are documented for each casting run, allowing ease of traceability.

    Showing intricate detail of sand castings

    What is Sand Casting?

    Airset sand casting, or no-bake sand casting, is a modern process that uses chemically bonded sand to create moulds. The foundry industry widely uses this process to produce complex and large metal components. Airset sand casting offers several advantages compared to traditional sand casting methods, making it a popular choice for manufacturers.

    One of the primary benefits of airset sand casting is its ability to produce intricate and accurate castings with a high degree of dimensional stability. The chemically bonded sand in this process provides better mould strength and a smoother surface finish, resulting in minimal post-casting machining requirements. This saves time and reduces material wastage, making the process more cost-effective.

    Superior Capabilities

    Furthermore, air-set sand casting is known for its superior casting integrity and improved mechanical properties. The chemically bonded sand creates strong mould structures, producing high-quality castings with excellent surface detail and tight tolerances. This makes air-set sand casting suitable for applications where precision and structural integrity are crucial.

    Environment

    In addition to its superior casting capabilities, airset sand casting also offers environmental benefits. The process utilises sand moulds that can be easily recycled, reducing waste and minimising the overall environmental impact. Using chemically bonded sand also eliminates the need for complex and time-consuming mould preparation, contributing to a more efficient and sustainable manufacturing process.

    Overall, airset sand casting is a versatile and reliable casting method that has revolutionised the production of metal components. Its ability to produce complex shapes, high-quality surface finishes, and solid and precise castings makes it an ideal choice for various industrial applications, from automotive and aerospace to machinery and equipment manufacturing. With its numerous advantages, airset sand casting continues to play a significant role in advancing modern foundry technology.