Abstract: Taking a heavy truck engine cylinder head as the research object, through the process structure analysis and casting problem analysis, a process design method using sand 3D printing process to produce this kind of casting is proposed, which avoids the problems of low dimensional accuracy of inner cavity and difficult cleaning in traditional resin sand casting. At the same time, combined with the simulation analysis of the casting structure and Magema software during the process design, the casting process design of the pouring system, riser and cold iron is optimized to avoid the internal defects of the casting such as shrinkage hole, shrinkage loose, porosity, sand inclusion, etc., and ensure the product quality and the progress of new product development.