3D Sand Printing

Additive Manufacturing Solutions for Endless Possibilities

Sand Printing

Our state-of-the-art 3D sand printing technology allows customers to develop integrated molds and cores while avoiding the tooling process, reducing costs and lead times.

Hoosier Pattern is proud to be an industry leader in additive manufacturing, and we set the bar high to exceed our customers’ expectations. With five in-house 3D sand printers and an experienced team, Hoosier Pattern continues to deliver the industry’s best integrated molds and cores every day.

Benefits of 3D Sand Printing

Design
Freedom

Design
Freedom

Experience what our services can do for you firsthand. With 3D printing for sand casting, the possibilities are nearly endless.

No
Middleman

No
Middleman

Design and print geometrically complex products, bypassing tooling fabrication to create the core or mold, typical of conventional casting methods.

Rapid
Prototyping

Rapid
Prototyping

With dramatically increased design freedom and the ability to easily scale production volumes, delivery can happen in days — not weeks or months.

Project Cost Reductions

Project Cost Reductions

A 3D sand printing machine can lower costs by minimizing material waste, optimizing production, and consolidating multiple components into a single object.

Production Scalability

Production Scalability

Our services can simultaneously print multiple parts in a single build, reducing lead times. We can integrate additional printers to meet increasing demand.

Build Volume Capacity

Build Volume Capacity

Our 3D sand printer’s job box has a build envelope of 70.86 x 39.37 x 27.56 inches. This lets us effortlessly scale your project. 

Client Success Stories

Kevin Lucas, SFO Foundry Engineer
Kevin Lucas, SFO Foundry Engineer
Goulds Pumps, ITT Inc.

Hoosier pattern is a valued vendor. The printed sand cores and molds are shipped quick, accurate and of great quality. The service and quality we receive from Hoosier allows us to improve casting quality with CAD perfect cores, and to support trials and sample castings with patternless molds and cores. The team at Hoosier is great to work with and they provide valued advice and feedback on our printed sand projects.

Kevin Lucas, SFO Foundry Engineer
Kevin Lucas, SFO Foundry Engineer
Goulds Pumps, ITT Inc.

Hoosier pattern is a valued vendor. The printed sand cores and molds are shipped quick, accurate and of great quality. The service and quality we receive from Hoosier allows us to improve casting quality with CAD perfect cores, and to support trials and sample castings with patternless molds and cores. The team at Hoosier is great to work with and they provide valued advice and feedback on our printed sand projects.

Kevin Lucas, SFO Foundry Engineer
Kevin Lucas, SFO Foundry Engineer
Goulds Pumps, ITT Inc.

Hoosier pattern is a valued vendor. The printed sand cores and molds are shipped quick, accurate and of great quality. The service and quality we receive from Hoosier allows us to improve casting quality with CAD perfect cores, and to support trials and sample castings with patternless molds and cores. The team at Hoosier is great to work with and they provide valued advice and feedback on our printed sand projects.

Our 3D Sand Printing Process

1CAD File

Once we receive your custom CAD file, we’ll plug it into one of our job boxes. Each is roughly the size of an average refrigerator, and we fill them to the top with different molds and cores.

2Layer-by-Layer Printing

Next, we load the job box into the 3D sand printer. The print head applies binder to each layer of sand. The mixture of binder on the media creates multiple thin layers to eventually form the mold or core.

3Project Completion

After an average of 22 hours, the project is fully printed. We then let the 3D printing sand machine rest for around an hour to ensure everything is fully bonded. A vacuum is used to remove the un-bonded sand as parts are extracted.

Ensuring Quality Through Every Step

At Hoosier Pattern, when you win, we win.

With our 3D sand printing process, customers can expect a 10-day turnaround time on many of our projects. We can also ship quickly if needed.

Our foundry tooling and 3D-printed sand adhere to a rigorous quality-control system throughout each stage. We ensure all of our projects meet the industry’s highest possible standards.

Popular 3D Sand Printing Applications

Aerospace Components


3D sand printing is widely used in the aerospace industry for producing complex components with lightweight designs.

Automotive Prototyping


Automotive manufacturers often leverage 3D sand printing for the rapid prototyping of critical vehicle components.

Foundry & Metal Casting


Foundries tend to use additive sand manufacturing to create accurate molds and cores for their metal casting processes.

Print Custom Mold Solutions Directly from CAD

Print Custom Mold Solutions Directly from CAD

Hoosier Pattern’s 3D sand printers selectively dispense resin onto thin layers of specially engineered sand. This process produces accurate, uniform cores and molds, significantly reducing lead time.

We Bring Designs to Life

If you can design it, we can build it.

Our crew has worked with foundries for decades. We apply our knowledge to projects that run on smaller lines to assemble molds the size of a compact car. We have even printed mold sections that are used in a mold the size of a full-size van.

Check out this video to learn how our 3D Sand Printers turn designs into realities.

Incorporating Technology

Since our industry never stays static, incorporating the latest updates, technological equipment, and practices allow us to streamline our production process by providing our customers with the best molds and cores. Therefore, our staff and management team are constantly testing innovations and approaches to further our future product development.

Incorporating Technology

About Our Company
and Team

Hoosier Pattern has been on the cutting edge of innovation for over two decades. We’re consistently raising the bar in our industry while maintaining the highest quality for our customers.

Hoosier Pattern started in 1997 in a 3,500-square-foot space with just a couple of machining centers. Currently, we operate a 90,000-square-foot facility with state-of-the-art technology, allowing us to take on jobs from various customers across multiple industries.

Our management and team members understand our customers’ demand for expedient delivery times and that product excellence is a must. This expectation is the driving force behind our day-to-day operations. We have always been committed to “On Time Delivery” to keep up with the strict timelines that our customers demand.

Please take a moment and check out our highly trained and talented team. View our Employee Spotlight, and you will see firsthand how each team member plays a part in delivering the highest quality products and services.

About Our Company
and Team

Please click here to view our five-part video series to learn more about Hoosier Pattern’s culture and how we exceed our client’s expectations.

Let’s Talk!

Call or fill out our contact form today to receive a free quote for your next project.

  • Call (260) 724-9430

Frequently Asked Questions

It depends. The lead time for 3D sand printing services depends on several factors, including the complexity and size of the printed object.

In general, smaller and less complex objects tend to have shorter lead times, while larger and more intricate objects may require more time to complete.

To learn how long your specific project may take, please contact our team. We’ll provide you with a more accurate estimate based on your unique requirements.

There are some limitations and factors to consider as you begin your project. These include…

  • Adhering to minimum wall thickness requirements to prevent structural issues
  • Optimizing part orientation for improved surface finish and mechanical properties

As you work with our designers, we’ll help you be mindful of sand’s properties and the binding agents used in the process, as well as the constraints that dictate the maximum printable dimensions. 

There are several cost factors associated with industrial 3D printing, including…

  • Material expenses for sand and binding agents
  • Overall size and complexity
  • Lead time

All of these factors can contribute to the overall cost of printing with sand.

To learn what your 3D sand printing project will cost, contact us for an upfront estimate.

The accuracy of 3D sand printing can vary depending on several factors, including the specific technology used and the complexity of the printed object. That’s why choosing the right 3D Sand Printing company matters.

At Hoosier Patterns, we achieve high levels of accuracy and precision, thanks to our quality assurance process and advanced machinery. 

Many industries can benefit significantly from 3D sand printing. Most prominently, aerospace, automotive, and foundry use 3D sand printing for a variety of project types.