To solve the problems in long cycle

poor quality of the casting surface

difficulty to meet the requirements of dimensional accuracy and low yield etc in the trial of aluminum box castings fabricated by conventional process from an aviation factory

ProCAST software was employed to simulate and optimize the casting process

and its overall coated sand mold/core was prepared by selective laser sintering（SLS）.The optimization of the casting process and two castings were completed within 5 days

and the aluminum box with complex surface

good metallurgical quality and qualified geometry was produced sucessfully

of which the surface roughness and dimensional accuracy reach Ra 6.3μm and CT6～8

respectively.It fully met the requirements

thus the aviation aluminum box castings manufactured by precision rapid sand mold casting was realized.