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What Types of Casting Processes Do Manufacturers Use Today?

Did you know that 90% of durable goods involve the process of casting?

What even is casting? And what are the types of casting available?

Here’s a quick look at the types of casting processes manufacturers use today.

Sand Casting

The sand casting process uses silica material, such as sand. This can either be synthetic or naturally-bonded.

The sand is packed around wood or metal, and then once the pattern is removed, you can proceed with pouring molten metal in. In some cases, you can even add clay to improve particle bonding.

Sand casting is typically used for automotive products, like the engine blocks. It’s a good metal casting process for low-volume runs, as it’s relatively inexpensive for production costs. However, do note that it’s not as accurate as other processes.

Plaster Casting

Plaster casting is very similar to the casting process from above. However, instead of sand, you’d use gypsum and a strengthening compound.

A plaster pattern is used, which tends to crack and become defective after casting. Because of this, there’s a higher need for replacements.

With plaster casting, you get very smooth products that are more accurate than with sand casting. But naturally, this process costs more, especially since you need to replace the plaster often.

Investment Casting

This type of casting is also known as lost-wax casting. It’s a basic casting process that’s been around for thousands of years, which means it’s a tried and tested process.

Typically, investment casting is used for products that can’t be produced through machining or fabricating.

For each part, it uses a disposable wax pattern. The molten material is poured into this wax pattern. After cooling down, the pattern can be melted and reused after the casting product is taken out.

Investment casting is usually used in the automotive and aerospace industries. The military also uses this casting process.

This process is advantageous because it’s very accurate and precise. However, it does tend to be more expensive. So investment casting usually isn’t picked unless sand and plaster castings aren’t doable.

Die Casting

Die casting is also known as metal casting. This is where you use pressure to get your final product; that’s why it’s good for metal products. Do note that it’s usually used for non-ferrous metals and alloys.

In die casting, the metal is injected into a die under high pressure while in molten form. Because the process is so quick, none of the product hardens before being cast.

This casting process produces consistent and uniform objects, which makes it good for several industries. However, it has higher tool costs, which means die casting may only be worth it if you need to produce high volumes.

Understand the Types of Casting to Choose the Best One for Your Purposes

As you can see, there are several types of casting processes used in various industries. Now that you know a little more about casting manufacturing, you can make better-informed decisions for your business.

For more interesting reads, check out our other blog articles.