At HCW, we often engage with engineers who are designing new products but not familiar with the different casting processes available. Below is a table comparing common types of casting in North America. Keep in mind that your part geometry and project details play a large role in dictating the most suitable casting process for your application.
There are exceptions to pretty much everything noted below...the numerous inputs for each casting process introduces variations to the end product, and no two foundries are exactly alike. The type of sand (grain size) determines surface finish, the use of automation & robotics influence volumes, state-of-the-art molding equipment and customization might push the boundaries of what can typically be achieved, and many other variables ultimately determine what is possible. So, I suggest referencing the table below as a general guideline for each casting process.
If you have additional questions, don’t hesitate to reach out. taylor@hcwassoc.com
Casting Process | Part Price | Tool Price | Typical Volume | Min Wall Thickness | Surface Finish (RMS) | Part Complexity |
Die Cast | $ | $$$ | High | 0.085” | 63 - 200 | Medium, High |
Low Pressure Permanent Mold | $$ | $$$ | Medium | 0.18” | 200 - 400 | Medium |
Gravity / Tilt Pour Permanent Mold | $$ | $$ | Medium | 0.21” | 200 - 400 | Medium |
Green Sand | $$ | $ | Low, Medium | 0.21” | 250 - 900 | Low, Medium |
Airset / No Bake Sand | $$$ | $ - $$ | Low | 0.25” | 150 - 600 | Medium |
Investment | $$$ | $$ | Low, Medium | .090” | 125 - 175 | Medium, High |
Surface finish visual (RMS)
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