The Technology HouseSea, Air and Space

Metal Castings

The Technology House’s captive foundry can produce aluminum castings economically in quantities from one to 100 pieces, using either plaster mold or sand casting processes. Depending on the scope of your project, we can deliver your parts in as little astwo to fourweeks.

Plaster Mold Casting

With our plaster mold casting process and A356-T6 aluminum alloy, we can deliver roughly 80 percent of the properties of a die-cast part made of A380 aluminum alloy. Our plaster mold casting process offers a number of advantages over sand casting; for example, it allows casting part walls as thin as 0.060-in. and provides a very smooth surface finish.

Sand Casting

Our sand casting process can produce parts with walls 0.200-in. thick or thicker. It’s well suited for casting parts from aluminum, gray iron, ductile iron or steel.


The tooling used in both the plaster mold and sand casting processes is very similar. We can produce it quickly using loose patterns or models created using our stereolithography (SLA) rapid prototyping capabilities. We also employ SLA patterns to create matchplate or cope and drag tooling and core boxes. The specific tooling methods we use and tooling costs depend on the size and complexity of the casting, as well as the number of parts required. For smaller quantities (one to six parts) of small- to medium-sized parts, loose SLA tooling is the fastest, most cost-effective solution, with parts often available in as little as two weeks. Larger parts and quantities up to 100 require matchplate or cope and drag tooling, requiring four weeks for delivery of first samples.