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PREMIUM SAND CORE
MANUFACTURING FOR FOUNDRIES
3D Tooling
At Founders, we are developing a new approach to rapid foundry tooling using 3D printed sand matchplates, cope plates, and drag plates. Instead of waiting weeks or months for traditional tooling, we can print tooling geometry directly in sand and then reinforce it through multiple proprietary resin penetration processes. The result is a rigid tooling surface with hardness characteristics similar to traditional board materials like Ren, designed to be pressed into foundry sand molds for short-run, prototype, and development casting work.
This technology is still in active R&D, and we are continuing to evaluate durability, wear life, handling limits, and repeatability. While these tools are not intended to replace permanent production tooling in every application, they offer a promising bridge between one-off 3D printed sand molds and full traditional pattern equipment. Our goal is to help foundries move faster, test designs earlier, and reduce the cost and lead time of getting casting projects into the sand.
Sand Reclamation
Founders is also advancing research into thermal sand reclamation as part of our long-term commitment to cleaner, more efficient core and mold production. Thermal reclamation uses controlled heat to remove residual binders and organics from used foundry sand, allowing a higher percentage of sand to be recovered and reused in future production.
For Founders, this has the potential to reduce waste, lower raw material demand, improve sand consistency, and support a more sustainable manufacturing process. It represents an important next step in building a more vertically integrated and environmentally responsible sand core operation.
This capability is currently in development and expected to be coming to Founders soon. As we continue testing and evaluating the process, our goal is to bring customers a more efficient production model that supports both performance and responsible material reuse.
