In this work comparison of hybrid rapid moulds (prepared with three dimensional printing shells supported with dry, green and molasses sand) have been made for techno-economic analysis, for zinc (Zn) alloy shell casting. The comparison has been made on the basis of mechanical properties and dimensional accuracy. Time-temperature curves have been drawn to understand solidification of molten Zn alloy in hybrid moulds of different thicknesses. The results of study suggest that it is feasible to reduce shell wall thickness of hybrid mould cavity from recommended 12mm to 1mm. All castings prepared are consistent with the permissible range of IT grades and are acceptable as per ISO standard UNI EN 20286-1 (1995). Further green sand based hybrid prototypes at 3mm shell wall thickness, shows better dimensional accuracy and mechanical properties.