casting methods

Choosing the ideal casting method depends on several factors related to the part being produced, its application, and the manufacturing process

Casted Parts Various

How to decide the ideal Casting Method ?

Complex Shapes with Fine Details

Investment Casting

  • Suitable for intricate shapes with tight tolerances.
  • Works with materials like steel, aluminum, titanium, and nickel-based alloys.
  • Excellent for high-temperature alloys used in aerospace.

Sand Casting

  • Can handle complex shapes, but fine details may require secondary operations.
  • Suitable for cast iron, brass, aluminum, and steel.

Die Casting

  • Limited to moderately complex shapes.
  • Common for aluminum, zinc, magnesium, and copper alloys.

Permanent Mould Casting

  • Best for moderately complex shapes.
  • Suitable for aluminum, magnesium, and some copper alloys.

Dimensional Accuracy

Investment Casting

  • High accuracy (+/- 0.05 mm per cm).
  • Excellent for alloys like titanium and nickel requiring precision.
  • Minimal machining required.

Sand Casting

  • Moderate accuracy (+/- 0.5 mm per cm).
  • Often used for cast iron, steel, and aluminum parts that will be machined later.

Die Casting

  • Very high accuracy for aluminum and zinc parts.
  • Requires simpler geometries for mold ejection.

Permanent Mould Casting

  • Good accuracy with aluminum and magnesium alloys.
  • Tolerances may need post-machining for tight specifications.

Part Size

Investment Casting

  • Best for small to medium parts.
  • Works for parts from a few grams (jewelry) to 100+ kg (aerospace components).

Sand Casting

  • Suitable for very large parts (up to several tons).
  • Common for cast iron, aluminum, and steel used in industrial applications.

Die Casting

  • Limited to small to medium parts.
  • Weight range: less than 25 kg.
  • Commonly used for aluminum and zinc in automotive and electronics industries.

Permanent Mould Casting

  • Best for small to medium-sized parts (up to 25-50 kg).
  • Common materials include aluminum, magnesium, and copper alloys.

Material Options

Investment Casting

  • Works with a wide range: steel, stainless steel, aluminum, bronze, titanium, and nickel-based alloys.

Sand Casting

  • Versatile: handles ferrous (cast iron, steel) and non-ferrous metals (aluminum, brass, bronze, etc.).

Die Casting

  • Limited to non-ferrous metals (aluminum, zinc, magnesium, and copper alloys).

Permanent Mould Casting

  • Limited to non-ferrous metals (aluminum, magnesium, and some copper alloys).

Surface Finish

Investment Casting

  • Excellent finish (1.2-3.2 µm Ra) with titanium, steel, and aluminum.
  • Minimal post-casting polishing needed.

Sand Casting

  • Rough surface finish (3.2-12.5 µm Ra).
  • Cast iron and steel components often need machining.

Die Casting

  • Very smooth surface finish (1.0-2.5 µm Ra) for aluminum, zinc, and magnesium parts.

Permanent Mould Casting

  • Smooth surface finish (1.6-3.2 µm Ra).
  • Works best for aluminum and magnesium alloys.

Production Volume

Investment Casting

  • Economical for low to medium production volumes.
  • Common for titanium, steel, and nickel parts requiring high precision.

Sand Casting

  • Best for low production volumes or large, heavy components.
  • Common for cast iron and steel parts in prototyping and industrial equipment.

Die Casting

  • Excellent for high-volume production.
  • Aluminum and zinc alloys are ideal due to rapid casting cycles.

Permanent Mould Casting

  • Medium to high production volumes.
  • Common for aluminum and magnesium structural components.

Cost

Investment Casting

  • High upfront costs for molds, but lower per-piece costs for complex, high-precision parts.
  • Best for steel, aluminum, titanium, and nickel alloys.

Sand Casting

  • Low tooling cost but high labor cost.
  • Cost-effective for cast iron, aluminum, and steel in larger sizes.

Die Casting

  • High mold cost but low per-piece cost for high-volume runs.
  • Economical for aluminum, zinc, and magnesium parts in automotive and consumer goods.

Permanent Mould Casting

  • Moderate to high tooling cost.
  • Best for aluminum and magnesium parts requiring repetitive production.

Strength and Mechanical Properties

Investment Casting

  • Suitable for high-strength parts with steel, titanium, and nickel alloys.
  • Parts can be heat-treated for enhanced properties.

Sand Casting

  • Excellent for cast iron and steel requiring durability but with moderate strength.

Die Casting

  • Good for lightweight, strong parts made of aluminum or magnesium.
  • Limited by non-ferrous material selection.

Permanent Mould Casting

  • Produces dense, strong parts with low porosity.
  • Best for aluminum and magnesium structural applications.

Lead Time

Investment Casting

  • Long lead time due to mold preparation and process complexity.
  • Suitable for steel, aluminum, and titanium aerospace and medical components.

Sand Casting

  • Short lead time for prototypes or simple designs.
  • Common for cast iron and steel industrial parts.

Die Casting

  • Short lead time for mass production after mold preparation.
  • Ideal for aluminum and zinc parts in consumer products.

Permanent Mould Casting

  • Moderate lead time for mold preparation.
  • Best for aluminum and magnesium medium-volume production.

Applications

Investment Casting

  • Aerospace (turbine blades, nickel alloys), medical implants (titanium), and jewelry (gold, bronze).

Sand Casting

  • Large industrial components (engine blocks, cast iron pipes), heavy machinery parts (steel and aluminum).

Die Casting

  • Automotive components (aluminum engine blocks, zinc housings), consumer goods (magnesium casings), and electronics (aluminum and zinc enclosures)

Permanent Mould Casting

  • Structural automotive parts (aluminum wheels), small to medium-sized components (magnesium housings), and electrical enclosures (copper alloys).
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How can we help you ?

Novelty Structures stands out as a reliable partner in providing High-Quality Casting parts with complementary Post-Casting operations tailored to demanding industrial needs.

Contact our team to further discuss your needs.

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