A review of the influence of sand properties on parts manufactured by rapid sand casting through additive manufacturing

Sand casting remains widely utilized in both small- and large-scale production due to its simplicity, especially for small parts manufacturing. Recent innovations, such as rapid sand mold and core creation through additive processes, have significantly reduced lead times compared to traditional pattern-making methods, which often require weeks or months. However, products from rapid sand casting frequently exhibit defects, including poor surface finishes and inconsistent mechanical properties. This review critically examines key sand properties such as size and shape distribution, chemical composition, surface area, packing density, flowability, microstructure, and thermal behavior that influence the quality of rapid sand casting. Understanding, addressing, and optimizing these properties are essential for enhancing casting efficiency and improving product quality. Moreover, future research will explore cutting-edge technological advancements to enhance these properties and meet the growing demands of modern industry.