Robocasting vs Traditional Sand Casting: Which Is Right for You?
Robocasting vs Traditional Sand Casting: Which Is Right for You?
When you need a metal casting, you have options. Two of the most common methods are traditional sand casting and robocasting (also called patternless casting).
Both produce quality parts. But they work very differently—and the right choice depends on your project.
Here's a straightforward comparison to help you decide.
What's the Difference?
Traditional Sand Casting
Uses a physical pattern (usually wood or aluminum) to create the sand mold. The pattern is pressed into sand, removed, and molten metal is poured into the cavity.
Robocasting
Uses robotic arms guided by CAD data to carve molds directly from sand—no pattern required. The mold geometry comes straight from your 3D model.
When to Choose Robocasting
Robocasting makes sense when:
✅ You need 1-100 castings
✅ You're in the prototype or R&D phase
✅ Your design might change between runs
✅ You need parts fast (weeks, not months)
✅ Your geometry is complex with internal features
✅ You're replacing a legacy part and don't have a pattern
Bottom line: Robocasting eliminates tooling costs and lead time. You pay a bit more per part, but you skip the 5,000−15,000 pattern investment.
When to Choose Traditional Sand Casting
Traditional casting makes sense when:
✅ You need 500+ identical parts
✅ Your design is finalized and stable
✅ You're running ongoing production over months or years
✅ Per-part cost is your primary driver
Bottom line: If you're making thousands of the same part, the pattern pays for itself through lower per-piece costs.
The Hybrid Approach
Here's what smart manufacturers do:
1.Start with robocasting for prototypes and initial validation
2.Test and refine the design without tooling risk
3.Move to traditional casting once the design is locked and volumes increase
This approach minimizes upfront investment while you're still iterating, then optimizes cost at scale.
What We Offer
At One Off Castings, we specialize in robocasting and short-run production. We're built for:
Prototypes (1-10 parts)
Low-volume production (10-100 parts)
Legacy part replication
Bridge production while you wait for overseas tooling
If you need higher volumes, our parent company Southern Cast Products handles production-scale runs with traditional methods.
Not Sure Which You Need?
Send us your project details. We'll recommend the right approach based on your quantity, timeline, and budget.
📧 Email: info@oneoffcastings.com
📍 Location: Jonesboro, Arkansas