Moulding sand-related process parameters and properties were analyzed and optimized using design-expert software. The moulding sand mix was prepared using seven different particle sizes of the silica sand and weight percentages of clay and moisture contents, respectively. Three moulding sand parameters (Grain Size, % Clay, and Moisture contents) were designated as the inputs factors while moulding sand properties, viz, green compression strength (GCS), dry compression strength (DCS), green shear strength (GSS), dry shear strength (DSS), mouldability and green permeability were set as the outputs/response variables in the experimental design matrix. The models developed were successfully used to predict an optimal level of the constituents of the synthetic moulding sand and the moulding properties at 385.704 μm, average grain size, 75.985% silica sand, 19.610% clay, and 4.405% moisture contents. The results obtained showed the potential of both dry and green sandcasting for some cast iron and non-ferrous alloys components.