But regardless of the method that is used, aluminum sand casting should result in a mold cavity being formed. These air set molds can be formed using a casting flask that has both a bottom and a top part.

Next, the sand mixture is pressed together around the pattern of the mold cavity. The final part of the assembly will often require the sand to be vibrated in order to eliminate any holes or empty spaces in the mold. The casting liquid is ultimately what is poured into the mold cavity, and once the metal has cooled off and become solid, the casting can be finally divided from the sand mold. The mold will be subsequently destroyed.

The quality of the casting itself is almost entirely dependent on how well the molding process was completed, and the type of sand mixture that was used. Much of the sand castings that are made using green sand will deliver a rough texture. Green sand for aluminum will generally use olivine sand.