Sand casting occurs in six steps:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.

3. Remove the pattern.

4. Fill the mold cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mold and remove the casting.

There are two primary methods of sand casting — green sand and air set:

Green Sand Casting

Green sand castings are made using sand molds formed from wet sand which contains water and clay. The name "green sand" comes from the fact that the sand mold is not set — rather, it is still in the green or uncured state even when metal is poured into the mold. The sand is not green in color, but "green" in the sense that it is used in a wet state (similar to green wood). Sand castings made from coarse green sand impart a rough texture to the surface, and this makes them easy to identify. Castings made from fine green sand can shine as cast but are limited by the depth-to-width ratio of pockets in the pattern.

Air Set Sand Casting

The air set method uses dry sand bonded with materials other than clay. The use of a fast curing adhesive is referred to as no-bake sand casting because the molding sand sets at room temperature. Air set molds can produce castings with smoother surfaces than coarse green sand. This method is primarily chosen when deep, narrow pockets in the pattern are necessary, due to the expense of the plastic used in the process. Air-set castings can typically be easily identified by the burnt color on the surface. The castings are typically shot blasted to remove that burnt color. Surfaces can also be later ground and polished, with post-molding residue removed via grinding or shot blasting.