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Frequently Asked Questions (FAQ)

Our clients often ask questions such as:
 

  • Which casting method should I use for my project?

  • Which casting method is the best for quality?

  • Which casting technique is the cheapest?

  • Which casting method should I use if I only need a few parts?

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We have created a comprehensive FAQ and comparison table to help answer some these above questions.

Download Casting Method Comparison (PDF)

Sand Casting

Pressure Die Casting

Investment Casting

Materials Cast

  • Almost any metal can be cast

  • Only metals with a low melting point can be cast.

  • Almost any metal can be cast

Size/Weight/Shape Capabilities

  • Huge range in size of castings from tiny to very large.

  • Fairly complex shapes can be cast.

  • Fairly intricate internal shapes can be produced.

  • Not feasible to cast thin material section.

  • Complex shapes can be cast.

  • Thin walls possible to achieve.

  • Casting size is limited by casting machine capacity.

  • Part geometry must allow for removal from die cavity.

  • High reliability and consistency.

  • Complex, intricate shapes and thin walls possible.

  • High dimensional accuracy.

  • No draft requirements on casting geometry.

  • Weights greater than approximately 50kg may become uneconomical.

Mechanical Properties

  • Fair to good

  • Generally better than sand casting

  • Fair

Surface Finish

  • Inferior surface finish (‘grainy’) and dimensional accuracy in comparison to other casting techniques.

  • Surface defects possible.

  • Usually requires further machining.

  • Very good surface finish. Smooth or textured finishes can be achieved.

  • High dimensional accuracy.

  • Minimal or no further machining required.

  • Excellent surface finish.

  • Often requires no further  machining.

Production Rate

  • High speed, low volume

  • High speed, high volume

  • Relatively slow

Cost

  • Low capital investment (low tooling cost).

  • Relatively low cost for one-off or small-scale production compared with other casting methods.  Not economical for large scale production.

  • Relatively easy and cheap to modify pattern.

  • Sand can be recycled.

  • Further machining costs may be incurred.

  • High capital investment required

  • (die-casting machine and tooling expensive).

  • Economical for high scale production. Not feasible for one-off or small scale production.

  • May reduce requirement for further machining

  • Expensive tooling and labour costs.

  • May be uneconomical for large weight castings.

  • Potential to create savings for larger/repeat volume production.

  • Surface finish capabilities may negate requirement for further machining which is the main cost-saving feature of this casting technique.

  • Wax can be re-used.

Typical Applications

  • Engine blocks, crank shafts, cylinder heads, equipment housing, propeller blades, gears.

  • Automotive parts, machine components, tooling, fittings and connectors, telecommunication components, sink faucets, pots and pans.

  • Aerospace parts, automotive parts, military equipment, high precision equipment and tooling, gears, golf clubs, metal furniture.

  • Which metal should I be using for casting?
    The amount of metals and alloys can be overwhelming to someone without any experience in the industry, especially with all the standards in place. It really depends on the purpose of the product you would like to cast which determines the suitable metal. For example, aluminium castings are strong, light and corrosion resistant. Contact our team for any questions your may have about your project. We will be more than happy to help you select the right metal for your purpose.
  • How long does the casting process take?
    Depending on which part of the project you are on, volume of production, casting method and complexity of design can all affect the turnover time of a casting run. However, you can always trust Adarsh to provide our clients with extremely fast turnover times as we pride ourselves on our efficiency. Contact us or visit us in our Perth office for our experts to evaluate the required time for your casting project.
  • Does Adarsh Australia make prototypes?
    Yes we do! We would love to assist you through the early stages of your project with design advice and our rapid and affordable prototyping services. Contact us or read more about our rapid prototyping services here!
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