<p>Chemically bonded sand cores and molds are an important part of metal casting technology, and the mold-metal interface is of great technical interest to the industry. The metal casting industry has been placing a strong emphasis on near-net-shape and thin-wall castings, while simultaneously maintaining increasingly stringent dimensional reproducibility requirements. The Thermal Distortion Test (TDT) has proven to be an effective laboratory testing methodology for measurement of distortion in chemically bonded sand binder specimens, and to determine the presence of undesired casting features for more than twenty-five years. The TDT generates real-time data of both longitudinal (axial) and radial deformation due to thermal distortion of a disc-shaped specimen. Though Thermal Deformation Curves (TDCs) provide valuable insight to the nature of specimen deformation, it may be arduous to interpret the result by technical people not acquainted with the test. This paper presents a 3D visualization tool that can assist design engineers in deeper comprehension of thermal deformation characteristics of the sand binder system throughout the casting process. Specific benefit to foundry engineers is 3D graphical visualization of the deformation at various temperatures and head pressure. The image produced can be used to define specific engineering strategies to prevent defects in casting, such as surface roughness, veins, penetration, cuts, washes, erosion, and extreme distortion. Therefore, the development of the 3D visualization tool along with other AI such as solidification simulation and digital twins to better understand the core/mold-metal interface and subsequently improve casting quality. Results for various sand binder systems are presented to illustrate the utility of the visualization tool.</p>