Process Description Typical Size Range Tolerances Surface Finish Min. Draft Required Min. Section Thickness Typlical Order Quantities Typical Tooling Costs Nominal Lead Times
V-Process Castings Extremely fine sand is “vacuum packed” around pattern halves. The pattern is removed and metal poured into the cavity. The vacuum is released and the casting removed Ounces to 150 lbs. +/-.010 for the first inch, then add +/-.002” per inch. Add +/-.010” across parting line 125 RMS None .125” Singles – 5,000 $4,000 – $12,000 Samples: 3 Weeks
Production: 1.5 – 2 weeks after approval
Sand Casting Treated (typically chemically) sand is molded around a pattern. The mold halves are opened and the pattern removed. Metal is poured into the cavity. The mold is broken and the casting removed. Ounces to tons +/-.030” to 6” then add +/-.003” per inch. Add +/-.020” – .090” across parting line 250 – 500 RMS 1° – 5° .25” Singles – 5,000+ $2,000 – $12,000 Samples: 2 – 6 weeks
Production: 2 – 6 weeks after approval
Investment (Lost Wax) A metal mold makes wax replicas. These are joined and surrounded by an investment material. Wax is melted out and metal is poured into the cavity. The molds are broken and the casting removed. Ounces to 20 lbs. +/-.003” to .125”
+/-.004” to .500”
+/-.005” to 3.0”,
then add +/-.003” per inch
63 – 125 RMS None .060” Under 1,000 $3,000 – $20,000 Samples: 8 – 10 weeks
Production: 5 – 12 weeks after approval
Permanent Mold Molten metal is poured into a steel mold. The mold is opened and the casting ejected. Ounces to 300 lbs +/-.015” to 1”, then add +/-.002” per inch. Add +/-.010” – .030” across parting line 250 – 400 RMS .1875” 1,000+ $8,000 – $60,000 Samples : 12 – 15 weeks
Production: 6-8 weeks after approval
Plaster Mold A plaster slurry is poured into the pattern halves. After setting, the mold is removed from the pattern, baked, assembled and metal poured into the cavity. The mold is broken and the casting removed. Ounces to 50 lbs +/-.005” to 2”, then add +/- .002” per inch. Add +/-.010” across parting line 63 – 125 RMS .5° – 2° .070” Singles – 250 $3,000 – $15,000 Samples: 2 – 10 weeks
Production: 4 – 8 weeks after approval
Die Casting Aluminum is pressurized and sprayed into a steel die. The metal solidifies, the die is opened and the casting ejected. Ounces to 15 lbs +/-.002” per inch. Add +/-.015” across parting line 32 – 63 RMS 1° – 3° .030” – .060” 2,500+ $20,000 – $100,000+ Samples : 12 – 15 weeks
Production: 6-8 weeks after approval

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