Casting Processes Overview for Manufacturing Buyers

The most economical casting method for low to medium volumes. A sand mold is formed around a pattern, then molten metal is poured into the cavity.

• Materials: Cast iron, steel, aluminum, bronze, brass
• Typical tolerance: ±0.5-1.0mm (CT 10-12)
• Min. wall thickness: 3-5mm
• Tooling cost: Low ($500-3,000)
• Best for: Large parts, low-volume production, prototype runs
• Lead time: 2-4 weeks for first samples

High-pressure injection of molten metal into steel molds (dies). Produces high precision, smooth surface finishes, and high production rates.

• Materials: Aluminum (A380, ADC12), zinc (Zamak 3, 5), magnesium (AZ91D)
• Typical tolerance: ±0.1-0.3mm (DIN 1688)
• Min. wall thickness: 0.8-1.5mm (aluminum), 0.5mm (zinc)
• Tooling cost: High ($5,000-50,000+)
• Best for: High-volume production, automotive, consumer electronics
• Lead time: 6-10 weeks for tooling, 3-4 weeks for production

A wax pattern is coated with ceramic, then wax is melted out to create a precise mold cavity. Produces excellent surface finish and dimensional accuracy.

• Materials: Carbon steel, stainless steel, aluminum, titanium, superalloys
• Typical tolerance: ±0.1-0.2mm (CT 4-6)
• Min. wall thickness: 1-2mm
• Tooling cost: Moderate ($1,000-5,000)
• Best for: Complex geometries, high-value parts, aerospace and medical
• Lead time: 4-8 weeks

Molten metal is poured into a rotating mold, using centrifugal force to distribute metal evenly. Ideal for cylindrical parts.

• Materials: Cast iron, steel, stainless steel, bronze
• Typical tolerance: ±0.3-0.8mm
• Best for: Pipes, tubes, bushings, rings, cylinder liners
• Tooling cost: Low to moderate
• Produces dense, porosity-free castings with excellent mechanical properties