Metal Casting Processes

The knowledgeable professionals at Baldwin Manufacturing are able to provide a full range of metal casting services as well as rubber and plaster mold castings to ensure you receive the components you need at the best price point and within your timeline. Below, you can learn more about the types of metal casting and mold casting services we offer, what materials are available, and more. Don’t hesitate to contact our team to learn more.

Investment Casting

This method allows for the most design freedom of any casting process, making investment casting a versatile solution to meet just about any production needs. Investment casting can be very cost effective, providing close tolerance, near-net-shape components. Additionally, investment casting is time saving with no drafts required and parts that often require no further machining.  We can use investment casting for most common and exotic alloys for commercial, industrial, and aerospace markets, including the manufacture of products like:

  • Turbine blades

  • Firearm components (triggers, hammers, etc.)

  • Golf clubs

  • Satellite components

Sand Casting

This process is the most cost effective and basic method of obtaining a simple casting of your parts. However, the part design requires relatively thicker wall sections and more draft. Components cast using this method will have less dimensional accuracy and reduced surface finish quality than other casting methods. Some common applications for sand casting include:

  • Cast iron products of medium to large size

  • Steel products of medium to large size

  • Casting for sculptures

Aluminum, Magnesium, and Zinc Alloy Die Casting

Die casting is ideal for high volume castings, offering low part costs for large volume orders. The tooling costs are higher to ensure the consistent quality in tolerance and surface finishes. We offer machine tooled options to ensure the lowest possible prices. The type of metal alloy will impact pricing and final results. The high-purity magnesium alloys available have physical and chemical characteristics that are superior to those of aluminum or zinc alloys. As a result, die casters can produce higher quality products faster, easier, and for less mney than ever before. Some items available via die casting include:

  • Auto parts

  • Lighting fixtures

  • Medical equipment components

 

See also our Die Casting Design Guide

Metal Injection Molding

Metal Injection Molding (MIM) is a low cost, high volume manufacturing process that produces parts to near net shape, resulting in lower secondary and machining operations. The MIM process uses powdered metal combined with binder to create a malleable material that can be fed into an injection mold to be shaped and solidified. The available process technology also lends itself to Ceramic Injection Molding (CIM) of small, high wear resistant components. MIM is often used for the following items:

  • Medical and dental tools and component parts

  • Firearms components

  • Aerospace components

  • Automotive parts

Powdered Metal Parts

Powdered metal parts are recommended for situations that require precision, small, low cost components requiring excellent finishes, close tolerances, no draft, complex shapes, and blind holes. Some examples are:

  • Gears (AGMA 7 - 12)

  • Pulleys

  • Bearings (self-lubricating)

  • Cams

  • Levers

  • Fasteners

  • Soft magnetics

 

Permanent Mold Casting

Permanent mold casting, also known as gravity die casting, produces parts that have better mechanical properties and surface finishes than sand castings as well as competitive part pricing. The final products are less porous than traditional die-castings, and we can achieve thicker wall sections for structural usage.  Common applications include:

  • Truck frames

  • Engine mounts

  • Large commercial door frames

  • Structural supports

 

Metal Forging

Metal forging is an economical and reliable solution for shaping almost any type of metal with minimal defects and little to no waste. The cost and time savings with metal forging are the main benefits. The process itself uses a hydraulic press to flatten metal bars into a specific shape creating a range of products, including:

  • Kitchenware

  • Hand tools

  • Hardware

  • Jewelry

 

Rubber Plaster Mold (RPM) Casting

RPM Casting is often used by companies as part of their "go to market" strategy, in order to obtain prototypes and smaller pre-production quantities of their products while awaiting die casting production. This process provides a method to create an as-cast part with thin walls, close tolerances, and a die cast quality surface finish.

Metal Casting Process Comparison Matrix

Note: The values listed below are for comparison only and are not absolutes.

Each design and each manufacturer is different. Therefore, these values will vary. “~” = approximate

 

 

 

 

 

 

 

Benefits of Working with Baldwin Manufacturing Company

Traditional manufacturing companies have established production capabilities and immovable infrastructure to create products in one way, and your business needs are molded to fit into their structure. At Baldwin Manufacturing, we do things a little differently. We’ve designed our business to provide the flexibility to allow your product specifications to dictate our processes, offering scalable, cost-effective options that use the highest quality materials.

A US owned and operated business, Baldwin Manufacturing’s main facility is located in Redwood City, CA, and we are proud to partner with world-class manufacturers in engineered metals and plastics who are located in California and Nevada. Our industry experts are passionate about helping business – like yours – customize component parts and end products that achieve their goals. There are other options for manufacturing products, but we know that our team will truly exceed your expectations, delivering fast, flexible, budget-friendly solutions.

Call Charlie now to solve your manufacturing challenges.

Baldwin Manufacturing has the technical expertise and manufacturing resources to meet the most demanding specifications. From prototype to large scale production while meeting ISO 13485 and AS9100 requirements.