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Palmer Associates P.O. Box 164 Hudson, NH 03051	Call: 603.889.5422   |   Fax: 603.881.9402 (dick@castingreps.com)
Cost Process Comparisons for Castings	Close Window

PROCESS	DESCRIPTION	SIZE RANGE	METALS	TOLERANCES	TOOLING COST & LEADTIME	MINIMUM SECTION THICKNESS	MINIMUM DRAFT REQUIRED	SURFACE FINISH	ORDERING QUANTITY
GRAPHITE MOLD	Precision molds are graphite. Metal is injected into the mold. Molds open & castings ejected. Similar to permanent Mold except no ceramic wash is needed.	Ounces to 10 pounds	ZA - 12 (zinc alloy)	1st inch: +/- .005". Additional inches: +/- .002". Across parting line: +/-.005"	$2,000 - $5,500 4-8 weeks	.100" (Can vary to .060" in areas)	2 degrees	125 RMS or better	Usually 300 and up
INVESTMENT (LOST WAX)	Metal mold makes wax replicas. These are joined, surrounded by investment material, baked out & metal poured in cavity. Mold is broken to remove casting.	Ounces to 150 pounds	Most all castable metals	+/-.003" to 1/4", +/-.004" to 1/2" +/-.005" to 3" then add +/-.003".	$3,000-$10,000 10-12 weeks	.60"	None	69 to 125 RMS	Aluminum under 1000 Others: All Quantities
DIE CASTING	Molten metal is injected under high pressure into hardened steel dies, often water cooled. Solidified part is ejected from open mold.	Ounces to 15 pounds	Aluminum, zinc, brass, & magnesium	+/-.002"/inch. Add +/-.015" across parting line	$5,000- $100,000 12-22 weeks	.030" to .060"	1 to 3 degrees	32 to 63 RMS	Usually 2500 and up
PLASTER MOLD	Plaster slurry is poured onto pattern halves, allowed to set, removed, baked and then assembled. Metal is poured in and once cooled, broken to remove parts.	Ounces to 50 pounds	Aluminum, zinc, brass, copper and bronze	+/-.005 to 2", then add +/- .002"/inch. Add +/-.010" across parting line	$2,000-$5,000 6-10 weeks	.070"	1/2 to 3 degrees	63 to 125 RMS	1-250
SAND CASTING	Sand is packed around a wood or metal pattern. Mold halves are opened to remove pattern. Metal is poured in and mold is broken to remove cooled part.	Ounces to tons	Most all castable metals	+/- 1/32" to 6" then add +/-.003" /inch. Add +/-.020" -.090" across parting line.	$1,000-$4,000 2-6 weeks	1/8"	1to 5 degrees	200 to 550 RMS	All
PERMANENT MOLD	Molten metal is poured into a ceramic coated metal mold. Mold is opened and cooled casting is ejected.	Ounces to 100 pounds	Aluminum, zinc, brass, bronze, lead & gray iron	+/-.015" to 1", then add +/-.002"/inch. Add +/- .010" to .030" across parting line.	$5,000 - $15,000 8-20 weeks	3/16"	2 to 4 degrees	150 to 300 RMS	500 and up

Note: the above chart is meant to be a basic guideline for comparison purposes only. For further detail please contact: Palmer Associates P.O.Box 164 Hudson, NH 03051 603.889.5422 (dick@castingreps.com)