The Art of Manual Sand Molding

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▪︎Video content
😚The video captures a close-up of the manual sand casting process. First, the pattern is fixed within the flask and covered with a fine sand mixture that has high bonding properties. Next, the craftsman spreads the sand evenly by hand and uses a wooden mallet to ram it firmly, ensuring the sand tightly conforms to every detail of the pattern. After compacting, the craftsman skillfully removes the pattern and creates a gating system to leave a precise shaping cavity inside the sand bed. Finally, the two mold halves are fitted together and clamped tightly, forming a hollow chamber ready for pouring molten aluminum to shape the product.

😉The primary purpose of this process is to create a hollow cavity with precise shape and dimensions within a durable sand mass to shape molten aluminum into the desired product. The significance of sand molding lies in its ability to manufacture complex geometries at a low cost, thanks to the readily available and reusable nature of the sand material. Furthermore, the sand mold plays a crucial role in heat resistance and gas permeability, ensuring the cast product achieves high precision, remains free of porosity defects, and maintains optimal mechanical strength.
🔥Things to keep in mind

Sand compaction: Note how the worker continuously compacts the sand with a mallet. The sand must be compacted sufficiently to withstand the pressure of the molten metal, but not so tightly that it eliminates the tiny gaps necessary for gas escape.

Surface smoothness: The finer and more evenly distributed the sand is in the first contact layer with the mold, the less further processing and grinding will be required after casting.

Mold tapping technique: Gently tapping around the mold box with a mallet before removing the mold helps to decisively separate the sand from the mold surface, preventing chipping or breakage of small details within the mold cavity.

Surface cleaning: Before joining the two mold halves, any loose sand particles inside the mold cavity must be blown away to prevent contamination (sand porosity) in the aluminum product.