Our prototypes made from core-block aluminum sand casting offer a comparable replication of the properties of die-cast and gravity die-cast components. Thanks to our extensive experience with cold-box sand molds (Pep-Set process), the resulting castings achieve mechanical properties similar to those of die casting and gravity die casting – making them ideal for testing phases and pre-series production.

Core blocks in aluminum sand casting always consist of an upper and lower section and, if necessary, additional cores assembled as a core package. This method enables the production of highly complex components with fine geometries and an exceptionally high-quality surface finish due to the use of ultra-fine sand.

Aluminum sand casting allows the realization of thin channels, undercuts, and complex geometries. Even bores and sealing grooves can be integrated directly into the casting process, eliminating the need for time-consuming machining steps. This significantly shortens project timelines for initial trials, pre-series validation, and the path to design freeze.

Prototypes produced from core-block aluminum sand casting offer significant advantages compared to prototypes made with conventional series production tooling:

1. Cost Savings: Initial parts with mechanical properties comparable to later series components.
2. Fast Modifications: Changes can be implemented with minimal effort – ideal for development phases and pre-series iterations up to design freeze.
3. High Design Freedom: The process allows for highly complex shapes and thin-walled components.
4. Maximum Precision: Our castings achieve accuracies of up to ± 0.3 mm and a surface roughness of Rz 20–25.
5. Thin-Wall Capability: We offer wall thicknesses as low as 2 mm for highly delicate structures.
6. Draft Angles: Draft angles of up to 0.5° are possible, ensuring high design flexibility.
7. Applicable Across Many Industries: Whether automotive, aerospace, mechanical engineering, electronics, or motorsport – our core-block aluminum sand casting prototypes provide tailored solutions for a wide range of applications.

Grohmann offers extensive expertise in prototype manufacturing using core-block aluminum sand casting. Our specialized processes – including cold-resin bonded core block methods – accelerate production and provide customized solutions tailored to your requirements.

Benefit from our long-standing experience and specialized know-how – from the first CAD dataset to the finished casting for your pre-series production.