Methods for creating partially reusable casting molds and/or multiple copies of a part using the same, related systems, molds, and parts

A computer-implemented method comprising:

• receiving data for a part to be made by casting, said data received from a three dimensional scanning tool or at least one drawing file;
• causing a binder jetting machine to generate reusable outer shells by printing and infiltrating the reusable outer shells with build material infiltrated with a relatively high strength material;
• causing the binder jetting machine to generate a plurality of sets of sacrificial inserts with the build material, each configured for assembly, one set at a time, inside the reusable outer shells to define a respective internal cavity for a respective copy of the part to be casted and define a respective mold for casting said respective copy of the part.

A system for creating multiple copies of a part by casting with a partially reusable mold, said system comprising:

• a set of reusable outer shells comprising infiltrated build sand manufactured by binder jetting and infiltration with a high strength material;
• and
• a plurality of sets of sacrificial inserts, each set being configured for assembly inside the set of reusable outer shells, one set at a time, to define a respective internal cavity for a respective copy of a part to be casted, wherein each of the plurality of sets of sacrificial inserts comprise non-infiltrated build sand manufactured by binder jetting, castings multiple copies of a part.