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Casting Process Comparisons V-PROCESS Castings - Extremely fine sand is 'vacuum packed' around pattern halves. The pattern is removed and metal poured into cavity. The vacuum is released and the casting removed. |
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| Typical
Size Range |
Tolerances |
Surface
Finish |
Min.
Draft Required |
Min.
Section Thickness |
Typical
Order Quantities |
Typical
Tooling Costs |
Nominal
Lead Times |
| Up to 150 lbs | ± .010" for the first 1", then add ± .002" per inch. Add a maximum .020" across parting line |
125-150 RMS |
None |
.125" |
All |
$3,000 to $14,000 |
Samples: 2 to 6 weeks Production: 2 to 6 weeks after approval |
| Sand Castings - Treated sand is molded around a wood or metal pattern. The mold halves are opened and the pattern removed. Metal is poured into the cavity. The mold is broken and the casting removed. | |||||||
| Typical
Size Range |
Tolerances |
Surface
Finish |
Min.
Draft Required |
Min.
Section Thickness |
Typical
Order Quantities |
Typical
Tooling Costs |
Nominal
Lead Times |
| Ounces to tons | ± 1/32" to 6", then add ± .003" per inch. Add ±.020" to .090" across parting line |
200-550 RMS |
1 to 5 degrees |
.25" |
All |
$800 to $4,000 |
|
| Investment (Lost Wax) Castings - A metal mold makes wax replicas. These are joined and surrounded by an investment material. Wax is melted out and metal is poured into the cavity. The molds are broken and the casting removed. | |||||||
| Typical
Size Range |
Tolerances |
Surface
Finish |
Min.
Draft Required |
Min.
Section Thickness |
Typical
Order Quantities |
Typical
Tooling Costs |
Nominal
Lead Times |
| Ounces to 20 lbs | ± .003" to 1/4" ± .004" to 1/2" ± .005" to 3", then add ± .003" per inch |
63-125 RMS |
None |
.060" |
Under 1000 |
$3,000 to $20,000 |
|
| Permanent Mold Castings - Molten metal is poured into a steel mold. The mold is opened and the casting is ejected. | |||||||
| Typical
Size Range |
Tolerances |
Surface
Finish |
Min.
Draft Required |
Min.
Section Thickness |
Typical
Order Quantities |
Typical
Tooling Costs |
Nominal
Lead Times |
| Ounces to 100 lbs | ± .015" to 1", then add ± .002" per inch. Add ±.010" to .030" across parting line |
150-300 RMS |
2 to 5 degrees |
.1875" |
500+ |
$5,000 to $25,000 |
|
| Plaster Mold Castings - A plaster slurry is poured into the pattern halves. After setting, the mold is removed from pattern, baked, assembled and metal poured into the cavity. The mold is broken and the casting removed. | |||||||
| Typical
Size Range |
Tolerances |
Surface
Finish |
Min.
Draft Required |
Min.
Section Thickness |
Typical
Order Quantities |
Typical
Tooling Costs |
Nominal
Lead Times |
| Ounces to 50 lbs | ± .005" to 2", then add ± .002" per inch. Add ±.010" across parting line |
63-125 RMS |
1/2 to 2 degrees |
.070" |
Prototypes up to 250 pcs |
$3,000 to $15,000 |
|
| Die Castings - Steel dies, sometimes water cooled, are filled with molten aluminum. The metal solidifies, the die is opened and the casting ejected. | |||||||
| Typical Size Range |
Tolerances |
Surface Finish |
Min. Draft Required |
Min. Section Thickness
|
Typical Order Quantities
|
Typical Tooling Costs |
Nominal Lead Times |
| Ounces to 15 lbs | ± .002" per inch. Add ±.015" across parting line |
32-63 RMS |
1 to 3 degrees |
.030" to .060" |
2500+ |
$10,000 to $100,000 |
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