Granular refractory mineral is coated with mostly bentonite clay and water, and then compacted (molded) around a pattern. When the sand mold halves are pulled apart, the pattern removed, and the mold brought together again, molten metal is poured into the mold cavity.

The green sand molding process is used to make simple- shaped parts. The benefits are in lower-cost tooling, faster turnaround, and parts usually less costly than with other molding methods.

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Air Set (No Bake) Process

Lost Foam Casting (Expendable Pattern Casting)