NEXT GENERATION VS.
TRADITIONAL FOUNDRY PROCESS:
WHAT METHOD IS BEST FOR YOUR SAND CASTING?
Tooling methods continue to evolve and provide
flexibility for getting the best casting.
Requirements like size, volume, complexity,
budget, and turn-around time all play a role in
finding the best techniques for each specific
project. Any given method might be perfect for
one situation but less than ideal for another.
Exciting improvements in technology are making
robotically milled molds an affordable reality, and
falling polymer printing prices make 3D-printed
pattern equipment a viable option. These rapid
manufacturing techniques, coupled with dramatic
advancements in scanning capabilities, now arm
casting manufacturers with powerful technologies
that can be tailored specifically for every project.
However, traditional tooling still plays an
important role in the foundry industry.
Your casting manufacturer will be able to help
you determine the best tooling method for your
project, but it is important for you to be armed
with a basic knowledge of the strengths and
weaknesses of different tooling types.
In this whitepaper, you will learn the basic
considerations for each method of tooling,
including:
• How core, size and volume
impact tooling decisions
• Robotically milled molds
• 3D printed patterns
• Hybrid tooling
• How 3D scanning can be a
solution for worn/obsolete tooling or parts
• When traditional tooling still is best
WORLD-CLASS CASTINGS DELIVERED
3D-PRINTED AND ROBOTICALLY MILLED MOLDS

In general, for short-run, complex castings 3D-printed sand molds and/or cores The surface finish of castings produced
and/or those that require a prototype, are a nice option for smaller castings. with robotically milled molds may be
robotically milled molds or a 3D-printed While the variable cost to cast may make rougher than with traditional tooling, so if
mold are likely your best bet from a cost this option cost-prohibitive for castings smooth finish is critical to your casting
and timing standpoint. These “next that require specialty sands, this can be an performance, this method would not be a
generation” methods have evolved to the ideal method for prototypes and complex good choice.
point where they can achieve design designs that need refinement.
flexibilities and geometries that are not Polymer-printed patterns are less
possible even with traditional tooling. A hybrid process, with a robotically expensive than printed sand molds, but
milled mold and printed core, is a mid- they have a limited lifespan and require
cost option that can be a good fit for large post-processing.
3D technologies custom parts that have complex
can: geometries and are needed quickly.
• Shorten lead Robotically milled (patternless) molds
time by up to can be a great choice for custom, low-
70% volume parts or prototypes that require
• Decrease rapid production. The set-up and variable
upfront cost to cast is relatively low. Most robots
investment by have the ability to create molds for large
up to 30% castings with simple cores. A model is
• Eliminate required for robotically milled molds.
equipment
storage/
maintenance WORLD-CLASS CASTINGS DELIVERED
costs
3D SCANNING AS SOLUTION FOR WORN OR OBSOLETE EQUIPMENT OR PARTS
If your worn part needs to be replaced and
is obsolete, and/or the pattern equipment
is beyond its useful life or otherwise
unavailable, you need to find a quick
solution to maintain or resume production.
New technologies have made reverse
engineering an affordable option for
refurbishing legacy parts in a relatively
short amount of time, even when drawings
or models are not available.
Utilizing modern scanning technology
coupled with advanced modeling software,
castings can be recreated in a digital
space. This allows the engineering team to
fine tune your design prior to casting,
decreasing time-to-market and increasing
casting quality and performance.
At Badger Alloys, we start by using our
FARO arm laser scanner to generate a point
cloud – or dataset – from your existing
tooling equipment or casting. Once we have
a point cloud collected, we create a mesh
model and adjust any surface defects that
may have been revealed during scanning.
The surface mesh then becomes the
template to create the fully featured 3D
Scan of original pattern equipment through surface mesh and fully featured casting model.
model, which we use to run solidification
simulations on your part and determine
how to create the highest quality casting
the first time through. This 3D model
becomes the cornerstone for your casting
project, allowing our sales and engineering
staff to work with you to determine the best
tooling fit and materials for your project.
Replacing a damaged or worn part through
reverse engineering can be an opportunity
to improve overall part performance
through upgrades in materials and design.
WORLD-CLASS CASTINGS DELIVERED
SOMETIMES TRADITIONAL TOOLING IS THE BEST
Traditional wood and polyurethane
patterns maintain an important role
in the world of metal casting. This
type of tooling is still likely the most
sound investment for higher-volume
castings that require multiple
reorders over time.
Traditional tooling is certainly the
most flexible tooling method in terms
of size and complexity. Traditional
patterns tend to be higher cost.
However, they are built for long-term
use, so they are worth the
investment for mid- to high-volume
castings.
That said, the quality of the pattern
will dictate the quality of the end
part, so it is crucial to protect this
long-term investment by having it
created by a skilled craftsman.
Ideally, your pattern will be created
in collaboration with a foundry
engineering team that can be
involved in the entire process, as
engineering changes can be
expensive.
Keep in mind the potential additional
cost of storage. Look for storage in a
clean, secure environment –
preferably on site where your
castings are poured to eliminate the
risk of damage in transit. Some
foundries will store their customers’
tooling equipment at no cost.
WORLD-CLASS CASTINGS DELIVERED
 TOOLING METHOD COMPARISON

3D-Printed Hybrid – Robotically Robotically Milled Polymer Printed Traditional Tooling

Mold/Core Milled Mold Pattern (Wood, Urethane, etc.)
w/Printed Core
All Complex/multiple None or simple All All
Core

Smaller (20” sq. or smaller) Between 20” and 96” Large (up to 96” square Loose pattern up to 24” square All
Size mold)- BA Limit

Required Required Required Required Not needed

Model

As little as 2 weeks model to As little as 2 weeks model to As little as 1 week model to As little as 2 weeks model to Tooling plus normal casting lead
Turn-around casting casting casting casting time (4- to 6-week minimum)
Time
Low Low Low Medium (3-5 per year) High (More than 5 per year)
Volume (1-3 per year) (1-3 per year) (1-3 per year)

$$$$ $$$ $$ $$ $
Variable Cost
to Cast
$ $$$ $$ $$ $$$$
Set-up Cost

Prototypes and complex
Ideal for designs that need refinement
Specialty sands can be cost
Cautions prohibitive
▪ Prototypes and complex
designs that need
refinement
▪ Large custom, one-off parts
or prototypes that are
needed quickly
Perfect for large castings with
complex geometries
▪ Custom, one-off parts or
prototypes that are needed
quickly
▪ Large, low-volume castings
▪ The most cost-effective
decision between traditional
tooling and milling depends
on the part geometry
▪ Surface finish may be
rougher than traditional
tooling
Low run patterns with simple ▪ Simple parts
geometries and a limited lifespan ▪ Parts with complex cores that
require specialty sands or core
wires (e.g. those with thin core
passages)
▪ Mid- to high-volume castings
▪ Surface finish may be sacrificed ▪ Quality of the pattern will dictate
▪ Patterns can beWORLD-CLASS CASTINGS
very fragile and DELIVERED
the quality of the end part
require much post-processing ▪ Pattern equipment requires
storage, handling, and
maintenance
▪ Engineering changes can be
expensive
NEXT GENERATION VS. TRADITIONAL FOUNDRY PROCESS:
WHAT METHOD IS BEST FOR YOUR SAND CASTING?

Additive and subtractive manufacturing

offer many attractive options for castings
purchasers. While the impact of 3D and
robotic technologies continues to grow in
the castings industry, there is still an
important place for traditional tooling
methods. A more sophisticated foundry will
offer a suite of services that includes not
only on-site pattern makers and 3D/robotic
equipment but an engineering team that
can consult with you to match the variety
of options to your specific project
requirements.
To learn more about how Badger Alloys’
Robot and 3D Technologies can reduce the
lead time and capital costs involved with
your casting production, please contact
Steve Cooke, Vice President of Sales, at
sales@badgeralloys.com or 414.258.8200.
View Badger Alloys’ video on the advantages of
patternless molding
Author Brad Moore is Director of Sales
Engineering at Badger Alloys, Inc., a
full-service castings manufacturer that
encompasses a sand foundry, pattern
shop, and machine shop on its
campus in Milwaukee, Wisconsin. Brad
holds a degree in industrial
engineering from the University of
Wisconsin-Madison. He focuses on
process improvement, lean
manufacturing initiatives, and project
management to ensure customers’
needs for complex castings are met.
Brad leads Badger Alloys’ team of
engineers and has been responsible
for the installation and
implementation of the company’s first
robot and other cutting-edge
technologies.

WORLD-CLASS CASTINGS DELIVERED