Casting Comparison

Process Comparison
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 Equipment dependent oz. -200 lbs. no limitation- equipment dependent 50 – 200 lbs. Oz.- 150lbs oz. – 100 lbs. oz. – 30 lbs. oz. – 10 lbs. Oz-15lbs oz. – 20 lbs.
Tolerances approximations only Equipment and process control dependent ±.020″ 0 to 10″, add ±.001″/in., thereafter. Add minimum of .010″ across the Parting line and for cored features. Irons, Aluminum, brass +/- 1/32”/ft Steels +/- 1/16”/ft ±.020″ 0 to 10″, add ±.001″/in., thereafter. Add minimum of .010″ across the parting line and for cored features. ±.010″ 0 to 8″, add ±.0017′, thereafter. Add minimum of .005″ across the parting line and for cored ±.015″/in. 0 to 1″, add ±.002″/in. thereafter. Add ±.010″ to .030″ across the parting line. Typical +/-.0025 to +/-.010 Add ±.015″ across the parting Line. Typical ±.005″ Add ±.002″ across the parting line. Typical +/-.0025 to +/-.010 Add ±.015″ across the parting Line. ±.003″to 1/4″ ±.004″to 1/2″ ±.005″to 1″, then add ±.003″/in.
Flatness Within .020″ (geometry dependent) All alloys .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, except on cored areas. 500RMS typical 120-175 RMS, except on cored areas. 63-125 RMS , 150-300 RMS 32-63 RMS 25 RMS or better 32-63 RMS 63-125 RMS
Minimum Draft Required Zero to 3° 1° to 3° 1/2° to 3° Zero to 2° 2° to4° 1/2° to 3° 1° to 2° 1/2° to 3° None
Minimum Wall Section Typical:.140″-.187″Minimum:.080″ (geometry dependent) 1/4”-1/2” depending on size and gating options Typical:.187″-.500″Minimum:.150″ (geometry Dependent) Typical:.100″ -.187″Minimum:.040″(geometry dependent) Typical:.187″ .030″ in zinc and Magnesium .060” Aluminum .100″ .060”-.100” .060″
Typical Quantities All All All <2,000 >500 >2500 500-1500 – >2500 <1,000
Typical Tooling Price (N.R.E.) $500 – $5000 $500-$25000 Core box, equipment and volume dependent $500-$5000 Core box(s),and equipment dependent $3K – 15K $3K – 15K $5K – 250K $1.5K – 5.5K $5K – 250K $500-10K
Nominal Lead Times Samples: 1-6 weeks (depending on complexity) Production: 4-8 weeks Samples: 4-6 weeks (depending on complexity) Production: 4-10 weeks Samples: 2-8 weeks (depending on complexity) Production: 6-14 weeks Samples: 2-4 weeks (depending on complexity) Production: 1-5 weeks Samples: 10-16 weeks (depending on complexity) Production: 4-10 weeks Samples: 12-22 weeks (depending on complexity) Production: 2-8 weeks Samples: 3-6 weeks (depending on complexity) Production: 2-6 weeks Samples: 8-16 weeks (depending on complexity) Production: 4-8 weeks Samples: 8-12 weeks (depending on complexity) Production: 10-14 weeks
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