METAL CASTING PROCESSES
Permanent Mold, or Gravity Die Casting, produces parts that have better mechanical properties than sand castings, with better surface finish and a competitive part price. They are less porous than die-castings and can obtain thicker wall sections for structural usage. Common applications include, truck frames, engine mounts, large commercial door frames, and other structural applications.
This method allows for the most design freedom of any casting process and can be very cost effective by providing close tolerance, near-net-shape components. No draft is required and parts often require no further machining. Available in most common and exotic alloys for commercial, industrial and aerospace markets.
Rubber/Plaster Mold Castings
RPM Casting is often used by companies as part of their "Go To Market" strategy, in order to obtain prototypes and pre-production quantities 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.
This process is the most cost effective and basic method of obtaining a simple casting. However, the part design requires relatively thicker wall sections and more draft. Components cast using this method will have less dimensional accuracy and surface finish quality than other casting methods.
High volume castings, very low part cost and requires larger quantities to justify higher tooling cost. Consistant quality in tolerances and great surface finish. Using robotics to keep labor requirements low can lead to domestic competitiveness.
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 process technology also lends itself to Ceramic Injection Molding (CIM) of small, high wear resistant components.
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, etc.
The high-purity magnesium alloys 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 money than ever before.
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