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Manufacturing Insight: Sand Casting Services
Integrated Sand Casting and Precision CNC Machining Solutions for Complex Metal Components
Honyo Prototype delivers end-to-end manufacturing excellence by combining traditional sand casting expertise with advanced CNC machining capabilities. Our sand casting process excels in producing intricate, high-integrity metal parts across aluminum, iron, and bronze alloys, accommodating both low-volume prototypes and high-volume production runs. Where sand casting establishes the foundational geometry, our in-house CNC machining services ensure critical features meet stringent dimensional tolerances and surface finish requirements—eliminating supply chain fragmentation and accelerating time-to-market.
This integrated approach guarantees seamless transition from casting to precision finishing, maintaining material integrity while achieving ±0.005″ tolerances on secondary operations. By controlling both processes under one roof, we mitigate quality risks, reduce handling costs, and optimize lead times for components demanding complex internal passages or large-scale structural forms typical in aerospace, automotive, and industrial machinery applications.
Leverage our technical proficiency through Honyo’s Online Instant Quote platform. Upload your CAD files to receive a comprehensive manufacturability analysis and competitive pricing for sand casting, CNC machining, or combined solutions within hours—not days. This digital workflow empowers engineers to validate design feasibility and budgetary planning with unprecedented speed, ensuring your project moves from concept to certified production-ready hardware efficiently.
| Service Integration Benefit | Technical Outcome |
|---|---|
| Unified Sand Casting + CNC Workflow | Reduced total lead time by 30% vs. multi-vendor setups |
| In-House Dimensional Verification | First-article compliance to ISO 2768-mK without rework |
| Material-Specific Process Control | Optimized gating systems and machining parameters per alloy |
Partner with Honyo to transform challenging metal component designs into high-performance realities, backed by engineering rigor and responsive digital tools for prototyping through production.
Technical Capabilities
Honyo Prototype offers precision sand casting services integrated with advanced CNC machining capabilities to deliver high-integrity components for prototyping and low-to-medium volume production. Our process combines traditional sand casting with modern 3-, 4-, and 5-axis milling and turning operations to achieve tight tolerances and superior surface finishes. Below are the technical specifications for our integrated sand casting and machining services.
| Parameter | Specification |
|---|---|
| Casting Process | Green Sand Casting (Silica Sand with Clay Binder), No-Bake (Resin-Bonded Sand) |
| Casting Alloys & Materials | Aluminum (A356, A380, 6061, 7075), Steel (1045, 4140, 304, 316), Ductile Iron |
| Plastic Machining (Post-Cast Tooling or Prototypes) | ABS (Acrylonitrile Butadiene Styrene), Nylon (PA6, PA66) – machined to simulate or support cast metal prototypes |
| Machining Capabilities | 3-Axis, 4-Axis (rotary indexing), 5-Axis (simultaneous multi-axis contouring) |
| Turning Operations | CNC turning with live tooling, bar feeding, and sub-spindle options |
| Tolerance (Machined Features) | ±0.005 mm (±0.0002″) for critical dimensions; ±0.025 mm (±0.001″) for standard features |
| Surface Finish (Machined) | Ra 0.8 µm (32 µin) typical; down to Ra 0.4 µm (16 µin) with fine finishing |
| Maximum Part Size (Casting) | 1000 mm x 800 mm x 600 mm (39″ x 31.5″ x 23.6″) |
| Maximum Machining Envelope | 1200 mm x 800 mm x 600 mm (5-axis), 1000 mm diameter x 500 mm length (turning) |
| Secondary Operations | Deburring, heat treatment (T6 for aluminum, annealing/quench & temper for steel), anodizing, powder coating, passivation |
| Inspection & Quality | CMM, optical comparators, surface roughness testers, first article inspection (FAI), full PPAP documentation available |
Our sand casting process supports complex geometries and internal cavities, while our multi-axis CNC machining ensures tight tolerance compliance and excellent repeatability on critical datums and functional surfaces. Materials such as aluminum and steel are cast to near-net shape, then precision machined to final specifications. For non-metallic prototyping or jigs/fixtures, we machine ABS and nylon to complement metal components within the same production workflow.
From CAD to Part: The Process
Honyo Prototype executes sand casting services through a rigorously defined digital workflow designed for precision, efficiency, and client collaboration. This process integrates advanced AI with deep manufacturing expertise to minimize lead times and ensure first-time-right outcomes.
CAD Upload and AI-Powered Quoting
Clients initiate the process by uploading 3D CAD models via our secure customer portal. Our proprietary AI engine immediately analyzes the geometry, material specifications, and dimensional tolerances against our sand casting capability database. This AI system generates a preliminary quote within minutes, including a manufacturability risk score, estimated lead time, and cost breakdown. Crucially, the AI identifies potential geometric complexities requiring attention—such as undercuts, thin walls below 3mm, or non-optimized parting lines—before human engineering review begins.
Engineering-Led DFM Analysis
All projects undergo mandatory Design for Manufacturability (DFM) review by our senior casting engineers. This phase is not automated but leverages AI insights as a starting point. Engineers evaluate draft angles, rib thickness, gating system feasibility, and solidification simulation requirements. We provide clients with a detailed DFM report highlighting necessary modifications to prevent defects like shrinkage cavities or mold erosion. Client feedback is integrated iteratively through our portal, with typical resolution within 24–48 hours. Only upon client sign-off does the project proceed to production.
Controlled Production Execution
Approved designs move to manufacturing where our process ensures repeatability. CNC-machined patterns or 3D-printed cores are fabricated to precise specifications. Molding uses automated jolt-squeeze machines with furan resin-bonded sand for dimensional stability. Molten metal—ranging from gray iron to aluminum alloys—is poured under controlled conditions with real-time temperature monitoring. Critical quality checkpoints occur at shakeout (surface inspection), heat treatment (if specified), and final machining. Each casting undergoes dimensional verification against the original CAD model using CMM reports.
Certified Delivery and Traceability
Completed parts ship with full documentation including material test reports (MTRs), dimensional conformance data, and non-destructive testing results where applicable. All castings are traceable via our digital lot-tracking system, linking each component to specific melt chemistry records and process parameters. Standard lead time from CAD approval to delivery ranges from 10–25 days depending on complexity, with expedited options available. Final delivery includes packaging certified for industrial transit and compliance documentation meeting ISO 9001:2015 standards.
This integrated approach eliminates traditional quoting bottlenecks while ensuring engineering rigor—transforming sand casting from a conventional process into a predictable, data-driven manufacturing solution for prototyping and low-volume production.
Start Your Project
Looking for reliable sand casting services for your next project? Honyo Prototype offers precision sand casting solutions with fast turnaround times and strict quality control. Our manufacturing facility in Shenzhen is equipped to handle both prototyping and low-to-mid volume production runs, ensuring consistent results for your custom metal components.
Contact Susan Leo today to discuss your casting requirements and receive a competitive quote. Email us at [email protected] and let our engineering team support you from design to delivery.
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