1.1 Coated Sand Casting
Coated sand casting involves using sand that is coated with a resin binder. The sand is shaped around a pattern, and heat is applied to cure the resin, creating a strong, detailed mold. This method enhances surface finish and dimensional accuracy, making it suitable for complex geometries
1.2. Resin Sand Casting
Resin sand casting utilizes chemically bonded sand mixed with a resin. Patterns are formed, and the mixture is packed around them. Once cured, the mold is ready for pouring molten metal. This method provides excellent surface finishes and tight tolerances, ideal for precision components.
1.3. Green Sand Casting
Green sand casting uses a mixture of clay, sand, and water as a binder. Patterns are pressed into the damp sand to create molds. This traditional process is cost-effective and allows for good surface quality, though it may require machining for tighter tolerances.
1.4. Vertical Sand Molding
Vertical sand molding involves packing sand vertically around a pattern in a two-part mold. This automated process enhances mold strength and consistency, allowing for efficient production of high-quality castings with good surface finishes and moderate tolerances.
1.5. Lost Foam Sand Casting
Lost foam sand casting uses foam patterns that are coated and then surrounded by sand. When molten metal is poured in, the foam vaporizes, leaving behind the desired shape. This method offers good surface finishes and allows for complex designs but can be more expensive due to the intricate pattern-making process.

Coated Sand Casting: Best surface finish, surface roughness ranges from 6.3 μm Ra to 12.5 μm Ra (25 μm Rz to 50 μm Rz). Coated sand casting offers a superior surface finish compared to resin sand casting. The coating process involves applying a fine layer of material to the sand, which helps in forming a smoother, more refined surface on the final casting, sharp edges and finer patterns, improving the overall aesthetic quality of the casting.
Resin Sand Casting: Best surface finish; surface roughness ranges from 3.2 μm Ra to 12.5 μm Ra (12.5 μm Rz to 50 μm Rz).
Vertical Sand Molding: High-quality finish and consistent quality; surface roughness ranges from 6.3 μm Ra to 12.5 μm Ra (25 μm Rz to 50 μm Rz).
Lost Foam Sand Casting: Good finish; variability based on pattern quality; roughness ranges from 6.3 μm Ra to 25 μm Ra(25 μm Rz to 100 μm Rz).
Green Sand Casting: Good finish but may require machining for critical surfaces; roughness ranges from 12.5 μm Ra to 100 μm Ra.

Green Sand Casting: Lowest cost due to simple materials and processes.
Vertical Sand Molding: Moderate cost, efficient for high volumes.
Resin Sand Casting: Moderate to high due to resin use.
Lost Foam Sand Casting: Higher cost due to process complexity.
Coated Sand Casting: Highest cost from precision requirements and materials.

Resin Sand Casting: Offers tight tolerances, making it ideal for precision components. DCT4 ~ DCT7, GCT3 ~ GCT5
Coated Sand Casting: Provides good to tight tolerances, suitable for applications requiring high dimensional accuracy. DCT7 ~ DCT9, GCT4 ~ GCT7
Lost Foam Sand Casting: Achieves moderate to tight tolerances, though variability can occur based on pattern quality. DCT9 ~ DCT13, GCT5 ~ GCT8
Vertical Sand Molding: Delivers reasonable tolerances, with consistency aided by automation.CT9 ~ CT13, GCT5 ~ GCT8
Green Sand Casting: Generally offers the lowest tolerances among these methods, often requiring additional machining for critical dimensions. DCT10 ~ DCT13, GCT6 ~ GCT8