| Process | Precision Sand Castings | Green Sand Castings | No-Bake Sand Castings | Plaster Molding | Permanent Mold | Die Casting | "Graphite" Permanent Mold | Semi-Solid Casting | Investment (Lost Wax) Castings |
| Common Alloys | Aluminum, Zinc, Magnesium | Any Castable Alloy | Any Castable Alloy | Aluminum, Zinc, Magnesium | Aluminum, Zinc, Brass | Aluminum A380, A413, A360, A383 Zinc #3, #7, #5 ZA8 Magnesium AZ91D | Aluminum and Zinc | Aluminum A356 357 355 319 A390 380 | Any Castable Alloy |
| Typical Size Range | oz. - 200 lbs. | No limitation (equipment dependent) | 50 - 200 lbs. | oz. - 150 lbs. | oz. - 100 lbs. | oz. - 30 lbs. | oz. - 10 lbs. | oz. - 15 lbs. | oz. - 20 lbs. |
| Tolerances | ±.020" 0–10", add ±.001"/in. thereafter. Add ±.010" across parting line & cores. | Irons, Aluminum, Brass ±1/32”/ft; Steels ±1/16”/ft | ±.020" 0–10", add ±.001"/in. thereafter. Add ±.010" across parting line & cores. | ±.010" 0–8", add ±.0017 thereafter. Add ±.005" across parting line. | ±.015"/in. 0–1", add ±.002"/in. thereafter. Add ±.010"–.030" across parting line. | ±.0025"–.010" + ±.015" across parting line. | ±.005" + ±.002" across parting line. | ±.0025"–.010" + ±.015" across parting line. | ±.003"–1/4" ±.004"–1/2" ±.005"–1", add ±.003"/in. |
| Flatness | Within .020" (geometry dependent) | .30–.50” linear ft. (geometry dependent) | Within .030" (geometry dependent) | Within .010" (geometry dependent) | Within .015" (geometry dependent) | .008” up to 3” and .003”/in. after | .008” up to 3” and .003”/in. after | .008” up to 3” and .003”/in. after | Within .015" (geometry dependent) |
| Surface Finish | 125–175 RMS | 500 RMS typical | 120–175 RMS | 63–125 RMS | 150–300 RMS | 32–63 RMS | 25 RMS or better | 32–63 RMS | 63–125 RMS |
| Minimum Draft | 0°–3° | 1°–3° | ½°–3° | 0°–2° | 2°–4° | ½°–3° | 1°–2° | ½°–3° | None |
| Minimum Wall Section | Typical: .140"–.187" / Min: .080" | ¼”–½” (size & gating dependent) | Typical: .187"–.500" / Min: .150" | Typical: .100"–.187" / Min: .040" | Typical: .187" | .030" (Zinc, Mg), .060” (Aluminum) | .100" | .060”–.100” | .060" |
| Typical Quantities | All | All | All | < 2,000 | > 500 | > 2,500 | 500–1,500 | > 2,500 | < 1,000 |
| Tooling Price (N.R.E.) | $500 – $5,000 | $500 – $25,000 | $500 – $5,000 | $3K – $15K | $3K – $15K | $5K – $250K | $1.5K – $5.5K | $5K – $250K | $500 – $10K |
| Lead Times | Samples: 1–6 wks | Prod: 4–8 wks | Samples: 4–6 wks | Prod: 4–10 wks | Samples: 2–8 wks | Prod: 6–14 wks | Samples: 2–4 wks | Prod: 1–5 wks | Samples: 10–16 wks | Prod: 4–10 wks | Samples: 12–22 wks | Prod: 2–8 wks | Samples: 3–6 wks | Prod: 2–6 wks | Samples: 8–16 wks | Prod: 4–8 wks | Samples: 8–12 wks | Prod: 10–14 wks |
