Rapid Steel Casting Prototyping with 3D Printed Molds
Rapid prototyping at Eagle Alloy allows customers to develop and test new cast parts without committing to long-lead tooling. By integrating 3D-printed sand molds into our airset casting process, we provide an agile, tooling-free solution for low-volume production, iterative design, or replicating legacy parts.
How Rapid Prototyping with 3D-Printed Sand Molds Works
Our team collaborates with trusted additive manufacturing partners to create precision sand molds and cores directly from your CAD models. These printed components are combined with traditional airset molding workflows at Eagle Alloy to produce accurate, full-density steel castings.
Typical process steps include:
- Finalizing CAD models and gating strategies
- Printing mold components with bonded sand
- Pouring molten steel in-house using Eagle Alloy’s high-capacity induction systems
- Post-cast inspection with 3D scanning and CMM tools
By avoiding hard tooling, we significantly reduce setup time and cost for parts that may never require high-volume production.
When to Use Rapid Prototyping for Steel Castings
Rapid prototyping is the ideal fit for casting projects when:
- You need functional prototypes before investing in permanent tooling
- You want to convert from fabrication to casting
- Design iterations are likely, and flexibility is key
- You require small quantities (25–100 pieces) without delays
Dimensional Tolerances and Casting Details
Our 3D printed mold castings closely match airset process tolerances. These include:
- Linear: ±0.063″ per inch
- Angular: ±1 degree
- Surface finish: 350–560 RMS
- Minimum wall thickness: 0.250″ (6.35 mm)
- Part weights: Typically range from 2 to 400 lbs
- Typical run sizes: 1 to 100 parts
These specs support detailed design validation while keeping material and process integrity in line with production standards.
Key Benefits and Limitations of Rapid Prototyping
Why customers choose Eagle Alloy’s rapid prototyping services:
- No tooling investment: Great for trials, transitions, or redesigns
- Shorter turnaround times: Molds can be printed in days, not weeks
- Supports complex geometry: Undercuts and channels without intricate cores
- Lower entry cost: Print only what you need, when you need it
- Seamless integration: Leverages Eagle Alloy’s full casting and finishing capabilities
See if 3D-Printed Sand Prototyping is Right for Your Project
Our engineers can help determine if 3D printed mold casting is the right fit for your timeline, design complexity, and quantity needs. Whether you’re bridging from prototype to production or switching away from welded fabrication, Eagle Alloy can guide you through the process with clarity and speed.
Request a Quote or Contact Our Team to start the conversation.