The purpose of the present investigations is to study the effect of moulding sand on decreasing shell wall thickness of mould cavities for economical and statistically controlled hybrid rapid casting solutions (combination of three dimensional printing and conventional sand casting) for zinc alloys. Starting from the identification of component/ benchmark, technological prototypes were produced at different shell wall thicknesses supported by three different types of sands (namely: dry, green and molasses). Prototypes prepared by the proposed process are for assembly check purpose and not for functional validation of the parts. The study suggested that a shell wall with a less than recommended thickness (12mm) is more suitable for dimensional accuracy. The best dimensional accuracy was obtained at 3mm shell wall thickness with green sand. The process was found to be under statistical control.