Green sand molding and chemically bonded sand molding are considered to be the most basic and widely used mold-making processes. This article describes the sand system formulation, preparation, mulling, mold fabrication, and handling of green sand molds. It lists the advantages and disadvantages of green sand molding. The article discusses the primary control parameters for the sand system formulation. It describes two basic types of green sand molds: flask molds and flaskless molds. The article provides a discussion on molding problems, including springback and expansion defects. It considers a variety of sand reclamation systems, including wet washing/scrubbing and thermal-calcining/thermal-dry...