General Die Casting Design Data Sheet
Having trouble deciding what casting process is most suitable for your needs? This guide will help you uncover the best casting or molding process for your application.
Note: The below information is meant to be a basic guideline for comparison purposes only. For more information or a competitive quote, please call 732-634-3000 or contact us now.
| Process | Aluminum Die Casting | Sand Casting | V-Casting | Investment Casting | Graphite Permanent Mold | Steel Die Permanent Mold | Plaster Mold |
|---|---|---|---|---|---|---|---|
| Size Range | Ounces to 50 lbs | Ounces to Tons | Up to 150 lbs | Up to 250 lbs | Up to 6 lbs | Up to 100 lbs | Ounces to 50 lbs |
| Tolerances | +/-.002″ to 1″ | +/- 1/32″ to 6″ | +/- .010″ to 1″ | +/- .005″ to 1″ | +/- .005″ to 1″ | +/-.015″ to 1″ | +/-.005″ to 2″ |
| Tolerances inches/inch thereafter | +/-.002″ | +/- .003″ | +/-.002″ | +/-.005″ | +/-.002″ | +/-.002″ | +/-.001″ |
| Parting Line Shift | +/-.005″ up to 10 sqin | +/-.020″ to .060″ | +/-.020″ | N/A | +/-.005″ | +/-.010″ to .030″ | +/-.010″ |
| Min. Section Thickness (premium) | .060″ | .110″ | .090″ | .050″ | .090″ | .125″ | .060″ |
| Min. Section Thickness (average) | .110″ | .110″ | .125″ | .080″ | .120″ | .187″ | .080″ |
| Min. Draft Required | 0.5 to 3 degrees | 2 to 5 degrees | Zero | Zero | 1 to 3 degrees | 2 to 4 degrees | 1 to 3 degrees |
| Surface Finish (RMS) | 32 to 125 | 250 to 500 | 125 to 150 | 60 to 90 | 63 to 90 | 150 to 300 | 63 to 125 |
| Average Tooling cost | $5K to $120K, based on part design | $1K to $5K | $3K to $6K | $2K to $9K | $3K to $8K | $5K to $20K | $3K to $9K |
| Average Tooling Lead Time (in weeks) | 6 to 14 | 2 to 6 | 2 to 4 | 6 to 8 | 2 to 4 | 8 to 20 | 2 to 6 |
| Typical Order Quantity | 5,000+ typical, minimum runs: 500 | All | All | All | All | 500+ | 1 to 250 |
| Metals | Aluminum 360 380 413 Zinc Zamac 3 Zamac 5 ZA-8 ZA-12 ZA-27 Magnesium | Most All Castable Alloys | Aluminum 319 356 535 | All Castable Alloys | Aluminum 356 319 ZA-12 ZA-27 | Aluminum Bronze Iron Lead | Aluminum Zinc Magnesium Brass |