What to keep in mind while selecting a casting method.
Casting is a manufacturing process that dates back to 1838, making it one of the most ancient in existence. There haven't been many changes to the basic casting process, but modern equipment are more complex, and technological advancements have opened you a variety of options for getting to your final product—or part, in this case. Die casting and investment casting are two procedures that are frequently used and extremely comparable. Keep reading to learn the differences between the various methods and the benefits and drawbacks of each so that you can make an informed decision about how to proceed with your next job.
The cooling time for the casting system as a whole is prolonged.
During the Die Casting Method
Die casting is the process of injecting molten metal into a steel die cavity that has been hardened. Extraction of metal from the tool and subsequent solidification is repeated. Die casting in a hot chamber or a cold chamber has subtle differences depending on the material you use. The hardened steel mold can produce anywhere from 150,000 to more than a million shots before it needs to be fixed or replaced.
The Casting Process for Investment Casting
As a result of the investment casting or "lost wax" process, the wax prototype of your item is formed and repeatedly immersed in liquid ceramic. After the ceramic solidifies, the wax is melted off and the mold is left in its place. The ceramic cavity is then filled with molten metal and the wax is removed. The ceramic mold is shattered and the metal casting is removed once it has solidified. With each part, a ceramic mold is broken and discarded, limiting how many times a wax pattern may be utilized in the mold. One week lead times for investment castings are attainable thanks to Signicast's automation of the entire process. The industry norm is 8-16 weeks.
How do I know which method is best for my project?
There is no one-size-fits-all answer for casting projects, and there are a variety of ways to approach each one. The following are some things to keep in mind while deciding which procedure is best for your component.
Selection of Substances
Zinc, aluminum, and magnesium are the most common non-ferrous metals used in die casting. Metals such as stainless steel can be cast via investment casting, along with other ferrous metals. When it comes to non-ferrous materials, both techniques have the same advantages. To employ stainless steels or copper alloys, investment casting is the best choice.
Volume yearly
The tool cost payback period should be considered while choosing on which casting technique to adopt. How many pieces must be produced in order to "break even" on the tooling costs. Die casting, on the other hand, is suited for big production runs and high-volume projects, while investment casting tooling is more expensive.
Time Spent in a Loop
There is a big difference in the cycle durations between investment casting and die casting when it comes to producing complex parts. When compared to traditional investment casting, die casting can generate anywhere from 3-4 shots per minute for conventional die casting to as many as 45 shots per minute for multi-slide die casting, making it more efficient. In many cases, a die cast part can be made completely automatically, with no involvement from a human.
Because up to 60% of the final part cost is determined by the cost cycle time, it should come as no surprise that investment casting is more expensive per part than die casting. Unlike a die casting, it uses a lot of manual labor, although the end product is remarkably comparable.
Casting is a manufacturing process that dates back to 1838, making it one of the most ancient in existence. There haven't been many changes to the basic casting process, but modern equipment are more complex, and technological advancements have opened you a variety of options for getting to your final product—or part, in this case. Die casting and investment casting are two procedures that are frequently used and extremely comparable. Keep reading to learn the differences between the various methods and the benefits and drawbacks of each so that you can make an informed decision about how to proceed with your next job.
The cooling time for the casting system as a whole is prolonged.
During the Die Casting Method
Die casting is the process of injecting molten metal into a steel die cavity that has been hardened. Extraction of metal from the tool and subsequent solidification is repeated. Die casting in a hot chamber or a cold chamber has subtle differences depending on the material you use. The hardened steel mold can produce anywhere from 150,000 to more than a million shots before it needs to be fixed or replaced.
The Casting Process for Investment Casting
As a result of the investment casting or "lost wax" process, the wax prototype of your item is formed and repeatedly immersed in liquid ceramic. After the ceramic solidifies, the wax is melted off and the mold is left in its place. The ceramic cavity is then filled with molten metal and the wax is removed. The ceramic mold is shattered and the metal casting is removed once it has solidified. With each part, a ceramic mold is broken and discarded, limiting how many times a wax pattern may be utilized in the mold. One week lead times for investment castings are attainable thanks to Signicast's automation of the entire process. The industry norm is 8-16 weeks.
How do I know which method is best for my project?
There is no one-size-fits-all answer for casting projects, and there are a variety of ways to approach each one. The following are some things to keep in mind while deciding which procedure is best for your component.
Selection of Substances
Zinc, aluminum, and magnesium are the most common non-ferrous metals used in die casting. Metals such as stainless steel can be cast via investment casting, along with other ferrous metals. When it comes to non-ferrous materials, both techniques have the same advantages. To employ stainless steels or copper alloys, investment casting is the best choice.
Volume yearly
The tool cost payback period should be considered while choosing on which casting technique to adopt. How many pieces must be produced in order to "break even" on the tooling costs. Die casting, on the other hand, is suited for big production runs and high-volume projects, while investment casting tooling is more expensive.
Time Spent in a Loop
There is a big difference in the cycle durations between investment casting and die casting when it comes to producing complex parts. When compared to traditional investment casting, die casting can generate anywhere from 3-4 shots per minute for conventional die casting to as many as 45 shots per minute for multi-slide die casting, making it more efficient. In many cases, a die cast part can be made completely automatically, with no involvement from a human.
Because up to 60% of the final part cost is determined by the cost cycle time, it should come as no surprise that investment casting is more expensive per part than die casting. Unlike a die casting, it uses a lot of manual labor, although the end product is remarkably comparable.