3D Printed Sand Mold Castings

OK Foundry designs and pours 3D printed sand molds to solve complex casting problems

Velie engine block casting 3d printed sand mold
3D printed sand mold and cores for 1912 Velie engine block casting

3D Printed Sand Molds for Economical Casting of Low Volumes

OK Foundry designs and pours 3D printed sand molds for complex short run iron castings and serial production of castings requiring 3D printed cores. 3D printed molds and cores are an economical solution for short run castings having multiple cores, complex cores, or difficult cores. 3D printed molds and cores can shorten the lead time for prototype or spare part castings, but tend to be most cost competitive for complex castings or small castings.

3D printed sand mold design for elevator reel casting
3D printed sand mold design for 300 lb. elevator cable reel casting

Complete 3D CAD/CAM Design Capabilities

OK Foundry has complete 3D CAD/CAM design capabilities including the latest version of Solidworks to provide design support for 3D printed sand mold and core design. Additionally, OK Foundry has built a complete end to end CAD/CAM system including FeatureCAM for 3D toolpaths for CNC milling of foundry patterns and simulation of CNC machining of castings. Regardless of your native 3D CAD software platform, OK Foundry can support a fully digital 3D casting design and development program.

1926 Alvis cylinder head casting from 3d printed sand mold
1926 Alivis cylinder head casting from 3D printed sand mold designed by Hunter Mechanical Design, LLC.

Mechanical Engineering Services for Casting and 3D Printed Mold Design

To make highly complex one-off prototype or antique engine castings feasible, OK Foundry works with Hunter Mechanical Design, LLC for casting and 3D printed mold design. Hunter Mechanical Design has developed expert 3D printed mold design skills working with OK Foundry on challenging casting projects like antique engine blocks and cylinder heads, and Hunter can provide complete Mechanical Engineering support including Finite Element Analysis (FEA), 2D and 3D engineering drawings for casting, machining and assembly for complete subcontracting of manufacturin engineering support.

3D Printed Sand Mold Galleries

1912 Velie Engine Block

OK Foundry reverse engineered a 1912 Velie engine block and poured a new casting from 3D printed sand molds and cores. Laser scanning of the block was performed by Direct Dimensions, Inc. and the casting and printed molds were designed by OK Foundry. The Velie engine block had tight water jacket passages that required complex coring and to economically cast one engine block that was engineered over 100 years ago was a challenge only possible using 3D printed cores and molds and the foundry know-how of OK Foundry, also over 100 years in the making.