The Box-Behnken response surface methodology was used to carry out optimization experiments on the 3D sand printing forming process. With tensile strength and gas evolution as the performance responses, the level ranges of three process parameters—resin jetting amount, curing agent addition amount, and printing layer thickness—were determined. The optimal process parameter combination was obtained through numerical simulation, and a low-pressure casting process was used to verify the trial-produced thin-walled impeller casting. The results showed that when the resin jetting amount was 1.44%, the curing agent addition amount was 0.21%, and the printing layer thickness was 0.30 mm, the tensile strength of the printed sand mold was 2.15 MPa and the gas evolution was 8.92 mL/g, close to the predicted values. Under the optimized process conditions, the trial-produced impeller casting had a complete and clear contour, and its quality met the technical requirements.
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