Casting – Rapid Prototyping & Production

Cast parts for Rapid Prototyping, as well as, Full Rate Production needs Molds are produced in state-of-the-art 3-D printers utilizing Artificial sand.

Rapid, Reliable Solutions

3D-Printed Molds vs. Conventional Casting

HBS leverages ExOne 3D printing technology to produce high-precision molds directly from digital CAD models, removing the need for traditional wooden patterns. Using polymer-based artificial sand, these molds maintain dimensional stability and eliminate the veining defects common with natural silica sand.

This cutting-edge approach allows faster prototyping, cleaner surfaces, and exceptional repeatability for both prototype and production castings. Key advantages:

Rapid Turnaround: 3D-printed molds produced in hours, not weeks.
Lower Costs: Up to 80% reduction in setup and tooling expenses.
Superior Accuracy: designs ensure consistent, high-tolerance results.
Defect Reduction: Artificial sand prevents expansion-related imperfections.
Design Flexibility: Easy to modify and optimize for complex geometries.

Industrial 3D sand printers with specifications table

3D printing process and cast metal component

3-D Printed Mold

Conventional Method (Wooden Pattern)

Natural vs atomized artificial silica sand

Chart comparing natural silica and artificial sands

Faster, Cleaner, More Precise Results

Engineered Sand for Superior Castings

Artificial Sand vs Natural Silica Sand

Silica sand expands with temperature over time, increasing possibility of veining defects
Artificial sand has low thermal expansion, preventing veining defects

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Speed, Precision, and Proven Results

Benefits and Advantages of HBS Casting Services

Reduced Non-Recurring Set-Up Fees

Our advanced 3D-printed mold technology cuts tooling costs to as low as 20% of conventional casting NRSU expenses. This efficiency allows faster project starts and measurable cost savings for every production.

Minimized Veining Defects

By using artificial sand molds with low thermal expansion, HBS prevents veining and surface imperfections common in silica-based castings. The result is cleaner, more consistent parts with less rework and waste.

Predictable & Repeatable

Through simulation-driven mold design, engineers fine-tune temperature, material flow, and cooling before casting begins. This ensures repeatable results, stable quality, and high confidence for each production run.

Short End-to-End Lead Times

HBS delivers production-ready castings in as little as 90 days, compared to traditional 360-day timelines. Our rapid process accelerates prototyping and reduces downtime across mission-critical programs.

State-of-the-Art

Advanced Casting Simulation Software

HBS uses advanced casting simulation software to model every stage of the pour, before a single mold is made. These simulations allow engineers to predict how molten metal behaves inside the mold, identify potential issues, and optimize the design for quality, consistency, and efficiency.

Color-mapped 3D thermal simulation of cylinders

Metal Flow / Temperature

Simulation contour map on vertical cylindrical components

Solidification

Thermal map on three vertical pipe sections

Shrinkage Prediction

CFD colored streamlines in pipe manifold

Metal Flow / Tracer

Proven Standards in Every Pour

Quality and Compliance Certified Casting Services

ISO 9001:2015

ISO 9001:2015 certification validates that every HBS casting process follows a rigorous quality management system. It ensures consistency, traceability, and continuous improvement that is critical for defense manufacturing where precision, documentation, and repeatability directly impact mission readiness and reliability.

Quality Assured from Design to Delivery

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CMMC Level 2

CMMC Level 2 alignment demonstrates HBS’s commitment to safeguarding Controlled Unclassified Information (CUI) throughout the production process. This certification reassures defense partners and primes that HBS operates under strict cybersecurity and data integrity standards required for DoD contracts.

Secure Manufacturing for Defense Programs

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Group ribbon-cutting ceremony outside new building

Precision Casting for Any Mission

Start Your Casting Project with HBS

Our casting solutions drastically reduce non-recurring setup costs and compress production timelines while maintaining superior quality. HBS’s integrated manufacturing and engineering teams allow seamless transition from prototype to sustainment, cutting risk for primes and government buyers alike. The result: mission-ready components delivered on schedule and within budget.

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About HBS Casting Services

Casting Frequently Asked Questions

What materials can HBS cast?

We support a range of ferrous and non-ferrous alloys, selected based on application and performance requirements.

How fast can a prototype be delivered?

Typical end-to-end lead time is around 90 days, up to four times faster than conventional casting cycles.

What industries do you serve?

Our castings support defense radar, electronic, and mechanical systems across naval and aerospace programs.

Next Step

Mission-Ready Starts Here.

Let’s connect and build the supply advantage your program demands.

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Casting – Rapid Prototyping & Production

3D-Printed Molds vs. Conventional Casting

Engineered Sand for Superior Castings