<p>This research paper introduces a new reverse engineering approach for rapid remanufacturing of failed or end-of-life (EoL) Al-alloy case study part called “spindle body” originally produced by traditional gravity sand casting (GSC), by rapid low-pressure sand casting (LPSC) process. The remanufacturing process begins with the extraction of surface information from the original physical part using an optical 3D scanner, followed by the creation of a CAD model using Zeiss Reverse Engineering® software. The risering and the gating systems were designed and optimized for two casting orientations based on thermal finite element (FE) simulations performed using ProCAST® software. The filling conditions were examined for both orientations and then optimized for only the retained one based on a coupled fluid flow-thermal computation. Based on the optimized as-casting design and the rapid LPSC process parameters, a physical experiment was conducted for the retained casting orientation. Macroscopic and microscopic observations of the casting did not show significant shrinkage defects, which is in good agreement with the numerical predictions. The 3D surface deviation between the cast and the CAD model was calculated and analyzed using Zeiss Inspect Optical 3D® software. This surface deviation shows a Gaussian distribution with a mean value of + 0.206&#xa0;mm and 3<i>σ</i> limits ranging from − 0.585 to + 0.998&#xa0;mm. This result proves that the casting dimensions are within the standard tolerances and confirms the effectiveness of the proposed method for the rapid replacement of critical failed parts with new castings of better quality.</p>