Cutting & Welding vs Sand Casting

Sand Casting compared to Fabrication

If you are using a metal fabrication, weldment, or machined shape more than 100 times a year for your product, you should explore the potential of casting.

The cast part can help by:

Reducing cost:
Eliminating welding
Shortening machining time
Speeding assembly by reducing the number of individual parts
Adding value:
Company names and logo may be cast into the part — even your phone number!
Weight can be reduced by thoughtful design, such as Increased cross-sections where needed or employing thinner sections where practical.

If you are developing an idea which may employ a metal part, we can help! Our staff include an engineer, a practical machinist and pattern maker, and foundry Molders with many years of experience. We have helped many customers develop and improve their products.

An Example:

A customer had developed a line of signage products which included a standard base, or “foot” shape, which was fabricate by cutting many shapes from aluminum plate, then jigging and welding. This base was then assembled onto the sign post.

The customer brought us one of their welded bases, and a sketch of what they thought a cast base should look like. We talked about what other features would be important and useful. Strength and weldability were of course discussed – but also the addition of the company’s name and telephone number. Design modifications are discussed which may facilitate the work in the foundry, or contribute to speed of handling and assembly at the customer’s shop.

Once we agreed to go ahead with the design, we outlined a plan for the creation of a molding tool (called a matchplate), and a plan for using that tool in our molding and casting process.


The customer spends less time in assembly and welding for each sign produced. And, the new cast part weighs less. Also, people noticing the sign as an example of a product needed, stop and find our customer’s telephone number – right on the sign post base!