Molding sand is at the heart of the sand casting process. It must hold a shape well and capture the fine details of a casting, yet be permeable enough to allow gases to escape. Under the strain of having the molding pattern removed from it, or while it is filled, it cannot crumble or sink on itself. When it is turned upside down it must not lose its form: the parts of a mold have to stay true while clamped together.
Metal casting is the process of pouring molten metal into a shaped space so that it will cool and harden in that form. For many items, this process can be less expensive than machining the part out of a piece of solid metal. Even though the idea behind it seems singular and simple, there are many ways foundries cast objects. How they make a metal casting mold will depend on the metals used, the size of the run, and the shape, symmetry, and complexity of the casting.
A designer, entrepreneur, or inventor gets an idea and begins the process to bring it to life. At first the idea is made of sketches and plans, research and design, but the designer’s focus is toward creating a physical object. There is no replacement for holding a mockup or prototype and seeing a vision come to life. Prototyping allows the designer to have confidence in their idea, work out production flaws, and woo investors or clients.