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ASHOK HANS CASTING LLP is an ISO 9001:2015 certified foundry with 48 years of legacy, delivering high-quality, cast iron castings across India.
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    Process

    Sand Casting Process

    Applications

    Our sand cast components are used in:
    • Automotive and engineering industries
    • Machinery and equipment manufacturing
    • Infrastructure and industrial applications
    • Custom and jobbing castings

    Ashokhans Casting LLP delivers reliable sand casting solutions through controlled processes, skilled workmanship, and a strong commitment to quality.

    From molten metal to precision-engineered components.

    Advantages of Our Sand Casting Process

    • Ability to cast complex and large components
    • Cost-effective tooling
    • Consistent quality and repeatability
    • Suitable for various industrial applications

    11. Inspection & Quality Checks

    • Visual inspection for surface defects
    • Dimensional inspection using measuring tools
    • Application-specific checks as required

    Only castings meeting quality standards proceed for dispatch.

    10. Fettling & Surface Cleaning

    • Gates, risers, and excess material are removed
    • Castings are cleaned using shot blasting or other methods
    • Surface finish is improved for inspection and machining

    9. Shakeout

    • After solidification, molds are broken to remove castings
    • Sand is recovered and reused after processing

    This step separates the casting from the mold material.

    8. Cooling & Solidification

    • Castings are allowed to cool under controlled conditions
    • Adequate cooling time is maintained to prevent cracks or distortion

    Controlled cooling improves structural integrity and dimensional stability.

    7. Pouring of Molten Metal

    • Molten metal is poured steadily into the prepared molds
    • Proper pouring technique is followed to avoid turbulence
    • Safety procedures are strictly maintained

    Correct pouring minimizes defects such as porosity and cold shuts.

    6. Metal Melting

    • Metal is melted in controlled furnaces
    • Slag and impurities are removed
    • Pouring temperature is monitored using temperature measuring instruments

    Controlled melting ensures consistent metallurgical properties.

    5. Mold Assembly

    • Cope and drag sections are aligned accurately
    • Gating and riser systems are checked
    • Molds are inspected before pouring

    Correct mold assembly ensures smooth metal flow and proper feeding during solidification.

    4. Core Making (If Required)

    For components with internal cavities or complex shapes:
    • Cores are manufactured using core sand and core boxes
    • Cores are properly baked or cured for strength
    • Accurate positioning of cores is ensured during mold assembly

    This step enables the formation of precise internal features.

    3. Mold Making

    • Prepared sand is packed around the pattern in molding boxes (flasks)
    • Proper ramming ensures mold stability
    • Patterns are carefully withdrawn to retain cavity shape

    Well-formed molds ensure accurate external geometry of the casting.

    2. Sand Preparation

    High-quality molding sand is essential for strong and smooth castings.
    • Sand is mixed with binders and additives in controlled proportions
    • Moisture content is monitored regularly
    • Sand properties such as strength and permeability are tested

    Proper sand preparation ensures good mold strength and gas escape during pouring.

    1. Pattern Making

    The sand casting process begins with pattern development.
    • Patterns are created as per component drawings and specifications
    • Allowances are provided for shrinkage, machining, and draft
    • Patterns are inspected and maintained for dimensional accuracy

    Accurate patterns ensure repeatability and consistent casting dimensions.

    Step-by-Step Sand Casting Process

    Overview of Our Sand Casting Process

    Our process converts molten metal into precision-engineered castings through a series of well-defined and monitored steps. Each stage plays a critical role in achieving defect-free and application-ready components.
    Sand casting is a versatile and reliable manufacturing process used to produce complex metal components with excellent strength and durability. At Ashokhans Casting LLP, our sand casting process is carefully controlled at every stage to ensure dimensional accuracy, sound metallurgy, and consistent quality.