Method for machining sand block into sand molding elements including sand molds and sand cores for metal casting foundry operations

A method for producing a sand core for interposition between a cope and a drag for use in foundry operations to produce prototype metal castings, comprising:

• providing a block of sand held together by binder material;
• and
• machining a pattern into the block of sand with at least one machine tool, forming the sand core adapted to be placed between the cope and the drag, the machining step including:
• (a) positioning the block of sand in a first position;
• (b) machining a first face of the block of sand while in the first position;
• (c) positioning the block of sand in a second position different from the first position;
• (d) machining a second face of the block of sand while in the second position;
• and
• completing the sand core by machining away sand from the sand block into granular sand waste without leaving any solid waste portion of the sand block connected to the sand core.