CustomPartNet
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September 30, 2026
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Updated September 30, 2026
Begin by filtering your supplier list down to those that fit your requirements, such as alloy capability, casting size range, or required certifications. Location matters too, since it can affect both shipping costs and lead time. For pump housings, the right foundry can be just as important as the design itself, particularly when the part has internal passages that must be cast accurately. Comparing sample castings against your own project is a smart way to judge fit. Samples show you the surface finish and feature detail a supplier can deliver, which is often more telling than a list of specifications. Use our supplier network on the right to compare qualified foundries, review sample parts, and request quotes.
Sand casting is the most widely used casting process. It uses expendable sand molds to form complex metal parts in nearly any alloy. Because the sand mold must be destroyed to remove the casting, production rates are typically lower than with other casting methods. That tradeoff makes it a strong fit for low to medium volumes and for large or geometrically complex parts.
The process uses a furnace, metal, pattern, and sand mold. The metal is melted in the furnace, then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The mold separates along a parting line so the solidified casting can be removed.
The cycle has six main stages:
Mold-making: Sand is packed around the pattern in each half of the mold. When the pattern is removed, the cavity that forms the casting remains. Internal features the pattern cannot form are created by separate sand cores.
Clamping: The cavity surface is lubricated, the cores are positioned, and the mold halves are closed and securely clamped so no material is lost.
Pouring: Molten metal is ladled from the furnace and poured into the mold until the cavity and all channels are filled. Filling must happen quickly to prevent early solidification.
Cooling: The metal solidifies inside the cavity and takes its final shape. The mold cannot be opened until the cooling time has elapsed.
Removal: The sand mold is broken and the casting is shaken out, often with a vibrating machine. Shot blasting may be used to clear remaining sand.
Trimming: Excess material from the gating channels is cut or sawed off, or removed with a trimming press.
Aluminum alloys are a popular choice for pump housings because they offer:
Low melting temperature, which keeps melting costs manageable
Lightweight castings that are easier to handle and install
Good castability for complex shapes and internal passages
Good thermal conductivity for heat dissipation
Natural corrosion resistance for many fluid and outdoor environments
Good machinability for ports, flanges, and sealing surfaces
Cost-effective patterns and tooling for low to moderate volumes
The main tooling for sand casting is the pattern, a full size model of the part that makes an impression in the sand mold. The pattern is made slightly larger than the part to allow for shrinkage as the casting cools. Internal surfaces that the pattern does not form are made with cores, which are produced in core boxes.
Patterns can be made from wood, plastic, or metal. Wood is inexpensive and easy to shape but wears faster, while metal costs more but lasts longer and holds tighter tolerances. Common pattern types include solid, split, match-plate, and cope and drag patterns.
Tooling costs vary depending on:
Casting size and envelope
Part complexity
Number and complexity of cores
Pattern material
Expected production volume
Pump housings often call for:
Sand cores for volutes, inlets, and outlets
Uniform wall thickness to limit hot spots and porosity
Generous inner radii at corners
Draft angles of 2° to 3° on walls parallel to the parting direction
Machining allowance on flanges, bores, and sealing faces
Aluminum sand casting is widely used to manufacture industrial pump components such as:
Centrifugal pump housings
Volute casings
Pump covers and end caps
Motor adapter flanges
Impeller casings
Bearing housings
Gearbox and drive housings
Valve bodies
Manifolds and fluid distribution blocks
Custom equipment housings
Pennsylvania suppliers support prototype and production programs for OEMs, machinery builders, and industrial equipment manufacturers throughout North America.
Aluminum combines light weight, good castability, corrosion resistance, and easy machining at a reasonable cost. Its low melting temperature also makes it one of the more economical alloys to pour in a sand casting foundry.
Costs depend on the metal, the mold sand, the core sand, and the production operations involved. Metal cost is driven by part weight and the unit price of the alloy. Tooling cost depends mainly on the size and complexity of the pattern and core boxes, and on how many castings you need. Get a quote from a supplier for an accurate number.
Yes. Sand cores form the internal holes and passages of a casting, and they can be shaken out after solidification. This allows complex internal features such as volutes and flow channels that would be difficult to produce otherwise.
Sand castings generally have a rougher surface than other casting methods, so critical features are usually machined. A machining allowance of about 0.0625 to 0.25 in. (0.16 to 0.64 mm) is commonly added to part dimensions to get a smooth surface on sealing faces, bores, and mounting flanges.
Most defects result from the solidification process. Common ones include porosity, hot tearing, unfilled sections, and surface projections. Uniform wall thickness, rounded corners, and well-planned gating help reduce them.
Yes. Many Pennsylvania suppliers offer pattern making, casting, machining, finishing, and assembly services, along with design support to help optimize your housing for casting.
Sand casting is well suited to low and medium volumes, and to large parts that would be impractical with other methods. Parts can range from a couple of ounces to several tons. Higher volumes may justify match-plate or cope and drag patterns for more automated production.
Get competitive quotes from Pennsylvania sand casting suppliers experienced with aluminum industrial components. Upload a CAD file, drawing, or product concept and receive quotes from qualified suppliers matched to your project requirements.
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