Die Casting:
Best suited for small to medium size parts with higher volume requirements.
100% recyclable material in some applications. Cast parts are preferred over plastic because they offer better strength, tolerate higher temperatures, and have a lower impact on the environment.
Advantages include minimal secondary finishing operations, high production runs, economical, tighter tolerances, thin walls, and consistency.
Disadvantages for die cast parts are weight (less than 30 grams/1oz) and size restrictions (24 inches/600mm), high initial costs, and some material limitations.
Best suited materials are copper, lead, aluminum, zinc, and tin based alloys
Investment Casting:
Best suited for parts that are small, include intricate design, and demand high reliability.
Advantages are accuracy, consistency, tight tolerances, thin walls, finished appearance, complex shapes, variety of alloys, and low material waste.
Disadvantages are increased piece price due to additional manufacturing processes, individual patterns required for each casting (increase tooling costs), and limited dimensions.
Most commonly used alloys are carbon, tool and alloy steel, and multiple grades of Stainless steel.
Sand Casting:
Best suited for parts that are simple in design and may be a large size
Advantages include low cost molds, low cost piece price, larger parts, and it produces less waste since material can be added to next run.
Disadvantages include surface finish, limited wall thickness, decreased tolerances, and lower porosity.
Common materials are aluminum alloys, brass alloys, cast iron and cast steel.
