Casting Processes: Sand Casting, Lost Wax & More

Sand casting at Becker Guss foundry Mödling Austria

Process 1

Sand Casting — the classic method

Sand casting is the most versatile casting process. It is used for single parts, prototypes and small series — in aluminium, bronze and brass. The process has remained essentially unchanged for centuries, but modern moulding technology delivers tight tolerances and clean surfaces.

1️⃣

Make the pattern

A pattern of the part is prepared — from wood, plastic, 3D print or metal

2️⃣

Make the sand mould

Sand is compacted around the pattern to create a negative mould

3️⃣

Melt the metal

Bronze, aluminium or brass is melted at 660–1000°C in the furnace

4️⃣

Pour and cool

The liquid metal is poured into the mould and allowed to solidify

5️⃣

Finish

The part is cleaned, ground and finished to specification

Process 2

Lost-Wax Casting (Investment Casting)

Lost-wax casting, also called investment casting or cire perdue, is one of the oldest precision casting processes in the world. It achieves very fine details and smooth surfaces that are not possible with sand casting.

1️⃣

Wax model

A wax model is made by hand or 3D printing — as detailed as the final piece

2️⃣

Ceramic shell

The wax model is dipped in liquid ceramic multiple times

3️⃣

Burn out the wax

The shell is heated — the wax melts out (hence "lost wax")

4️⃣

Pour the metal

Liquid bronze or aluminium is poured into the ceramic mould

5️⃣

Break the mould

The ceramic shell is broken away — revealing the highly detailed casting

Lost-wax investment casting at Becker Guss Mödling

3D scan and 3D printing for metal casting — Becker Guss

Digital processes

3D Scanning & 3D Printing

Modern digital technology complements traditional craft. With 3D scanning we can capture existing objects and use the data to make new patterns — useful for restorations or when no CAD model exists. 3D printing allows precise wax or pattern models to be made directly from digital files.

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3D Scanning

Precise digitisation of existing objects, sculptures or machine parts

🖨️

3D Printing

Patterns and wax models directly from CAD data

Casting Processes