This study is the first case in using 3D printing sand mold technology to manufacture casting tools in Taiwan. In order to rapidly and accurately fabricate casting tools for casting manufacturing, this study integrates design of casting methods, casting simulation, design of molds, 3D printing, and casting pouring engineering. The finished casting tools in this paper have been applied in mass production of sand mold and help shorten delivery time up to 40% and reduce the cost of the tool more than fifty thousand NTD. For similar application of new product development, 24 sets of various sand molds can be printed in one working process (the size of the job box 2000 × 1000 × 1000 mm). This innovative process has high potential in tool manufacturing for new product development and helps increase the applications of 3D printing technology in sand mold mass production industry.