Custom Sand Casting Services
The Federal Group USA is a premier global sand casting manufacturer that offers a wide range of high-quality metal casting services. Sand casting remains one of the most cost-effective, widely used, and efficient casting solutions, helping to reduce lead time and costs.
Request a QuoteUnmatched Experience
Manufacturing complex custom castings since 1980
Diverse Materials
Stainless steel, alloy steel, iron, aluminum, and more
Custom Applications
High and medium volume production solutions
High-Quality Standards
Quality management systems that are certified to ISO/QS/TS
Industries We Serve
Our products are made with durability and precision in mind. As a leading sand casting company, The Federal Group USA serves a wide range of industries, relying on decades of experience in sand casting. We use advanced technologies to provide the highest quality cast components to the industrial manufacturing, energy, and construction sectors.
Industrial Manufacturing
TFG USA produces custom parts for industrial machinery and plant infrastructure. Our sand casting services are a cost-effective solution for low volume runs, focused on creating reliable components that meet strict performance standards. Using advanced technologies like solidification modeling and 3D printing, we keep your costs low while producing quality precision parts.
Energy Sector
Bringing extensive experience to the manufacture of high performance parts for the energy sector, TFG is a leading sand casting manufacturer for components like turbines, pump housings, and valve bodies. Our quality sand casting services ensure that each part meets the energy industry’s demands for durability, able to withstand the extreme temperatures and high pressures these critical components are exposed to.
Construction and Beyond
From precision cast brackets to custom fittings and heavy duty parts for construction machinery, our custom sand casting solutions are designed to meet the specific needs of the construction industry. We work closely with our clients to deliver quality sand castings that meet the demanding conditions of construction environments.
What Is Sand Casting?
Sand casting is a type of metal casting technique that involves the use of sand to create a mold. Molten metal is poured into the mold to create the final product. This manufacturing process is used to create metal products in a wide range of shapes and sizes.
Is Sand Casting Right for Your Product?
Image above: A clevis manufactured via sand casting.
Sand molded castings are cost-effective but may not be the best manufacturing process for every product or part. Key things to consider are quantity, budget, production timeline, shape, dimensional accuracy, tolerances, and surface finish.
The Advantages of Sand Casting
The main advantages of this casting process include:
- Lower costs for low-volume production runs
- Suitability for fabricating large parts and components
- Ability to use ferrous or non-ferrous metals
- Shorter lead time compared to other processes
One of the most attractive features is that it has the lowest initial setup cost. The process is also easier to modify and reduces the cost of changes to the sand casting mold.
Due to these features, this method of casting is ideal for the fabrication of low- to medium-volume production runs, prototype castings, and the conversion of welded components to castings.
Our Sand Casting Process
Image above: Commercial stove burner manufactured via the sand casting process.
We offer a variety of sand casting methods and materials to suit your project, including:
- Greensand molding
- Resin sand molding
- Air set molding
Along with these processes, we offer a complete metallurgical analysis. With our state-of-the-art foundry, we can prepare metals for analysis to help reduce casting defects and process inefficiencies.
Our solutions also allow for the use of a wide range of materials including stainless steel, alloy steel, iron, aluminum, magnesium, brass, bronze, and copper. Our equipment includes magma solidification software to reduce or eliminate porosity. We also utilize a coreless induction melting furnace to increase productivity.
Our Sand Casting Equipment
- Magma Solidification Software: Using this software results in better pattern making and gating to reduce or eliminate porosity.
- Coreless Induction Melting Furnace With a fast heat-up time, this combines high productivity with maximum alloy flexibility.
- Channel Holding Furnace: The channel holding furnace combines high productivity with the economical operation and provides a continuous supply of ready-to-pour molten metal 24 hours a day.
- Automatic Sand Molding Machine: Made with mechanical automation and used for high volume casting, all molds have the same dimensions, tension, moisture content, and other properties.
The Federal Group’s Sand Casting Capabilities
Image above: A sand casted and machined product finished with a rust preventing paint. Manufactured by The Federal Group.
Our foundry capabilities have a wide range from 1 lb to 30,000 lbs per piece. Different materials and methods can be used to achieve the ideal result for your casting products:
Green Sand Molding
Castings are made using sand molds formed containing water and organic bonding compounds (typically clay).
Resin Sand Molding / Shell Molding
Castings are made with resin sand, which is a mixture of quartz sand and resin. Also known as a hard mold, the resin sand becomes very hard and solid after mixing and burning.
No-Bake / Air Set Molding
This sand casting process involves the use of chemical binders to bond the molding sand at room temperature. Heating is not necessary for this process.
Complete Metallurgical Analysis
- Our state of the art lab is fully capable of preparing metals for analysis.
- Microscopic and Macroscopic Analyses: Sectioning, mounting, polishing, and micro etching are done to prepare the metal for analysis.
- X-Ray Diffraction Analysis: We are also capable of preserving the specimen: This is a nondestructive technique for characterizing crystalline material or minerals.
- Fully Equipped Sand Testing Lab: Capable of testing all of the characteristics of prepared sand for casting, we have maximum control over processes. This identifies casting defects and process inefficiencies, resulting in superior products at a lower cost of operation.
Our Sand Casting Materials
Various metal material can be used for sand casting depending on the application and desired properties of the final product. We use the following materials in our sand castings:
- Alloy Steel
- Aluminum
- Brass, Bronze & Copper
- Cast Iron
- Grey, Ductile & White Iron
- Magnesium
- Stainless Steel/ Duplex 2205, 2507 & Zeron
Contact Us Today for a Free Sand Casting Quote
If you’re interested in getting a quote for your upcoming sand casting project, contact The Federal Group USA today. We’re happy to talk through our manufacturing process and any other metal casting services you may be interested in.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
