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A simple, cost effective approach to metal casting, sand casting becomes even more cost effective with the use of FDM printing.

Producing sand molds and cast metal parts is relatively straightforward and suitable for automated methods that can reduce cycle time and labor. However, fabricating the patterns is often difficult, time-consuming and expensive. The most common approach is to produce aluminum patterns using CNC machining. The biggest problems with this approach are the high cost and lengthy lead time. The potential for problems, such as incorrect shrink compensation and design flaws, means the initial pattern often must be redone, which adds to the expense and lead time. It is not usually practical to machine the intricate gate and runner systems on CNC machines because testing is required to finalize the design. Instead, the gate and runner system is cut from Ren board or a similar material and then hand–carved and sanded to the finished shape. Constructing the gating system adds expense and lead time.

Because of the problems associated with traditional pattern production, foundries have long been interested in 3D printing (also called additive manufacturing). With 3D printing systems available from Stratasys, foundries can fabricate patterns with either inkjet-based technology or FDM Technology. This results in substantial savings in cost, labor and time, ultimately speeding new product development.

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