Casting Manufacturing Process Comparison Table Chart

The following table compares casting manufacturing processes by advantages, disadvantagesand recommended application.

Casting Processes - see Casting Definitions, General Design Guidelines
Casting Process	Advantages	Disadvantages	Recommended Application
Sand More Information: Sand Cast Design Guidelines Casting Rib Design General Design Guidelines	Least Expensive in small quantities (less than 100) Ferrous and non- ferrous metals may be cast Possible to cast very large parts. Least expensive tooling	Dimensional accuracy inferior to other processes, requires larger tolerances Castings usually exceed calculated weight Surface finish of ferrous castings usually exceeds 125 RMS	Use when strength/weight ratio permits Tolerances, surface finish and low machining cost does not warrant a more expensive process
Permanent and Semi-permanent Mold More Information: Casting Rib Design General Design Guidelines	Less expensive than Investment or Die Castings Dimensional Tolerances closer than Sand Castings Castings are dense and pressure tight	Only non-ferrous metals may be cast by this process Less competitive with Sand Cast process when three or more sand cores are required Higher tooling cost than Sand Cast	Use when process recommended for parts subjected to hydrostatic pressure Ideal for parts having low profile, no cores and quantities in excess of 300
Plaster Cast More Information: Casting Rib Design General Design Guidelines	Smooth "As Cast" finish (25 RMS) Closer dimensional tolerance than Sand Cast Intricate shapes and fine details including thinner "As Cast" walls are possible Large parts cost less to cast than by Investment process	More costly than Sand or Permanent Mold-Casting Limited number of sources Requires minimum of 1 deg. draft	Use when parts require smooth "As Cast" surface finish and closer tolerances than possible with Sand or Permanent Mold Processes
Investment Cast More Information: Investment Casting Using Stereolithgraphy Casting Rib Design General Design Guidelines	Close dimensional tolerance Complex shape, fine detail, intricate core sections and thin walls are possible Ferrous and non-ferrous metals may be cast "As-Cast" finish (64 - 125 RMS)	Costs are higher than Sand, Permanent Mold or Plaster process Castings	Use when Complexity precludes use of Sand or Permanent Mold Castings The process cost is justified through savings in machining or brazing Weight savings justifies increased cost
Die Cast More Information: Casting Rib Design General Design Guidelines	Good dimensional tolerances are possible Excellent part-part dimensional consistency Parts require a minimal post machining	Economical only in very large quantities due to high tool cost Not recommended for hydrostatic pressure applications For Castings where penetrant (die) or radiographic inspection are not required. Difficult to guarantee minimum mechanical properties	Use when quantity of parts justifies the high tooling cost Parts are not structural and are subjected to hydrostatic pressure