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Casting

Precise Cast Castings

 

There are many different metal casting methods. At Precise Cast we have chosen two methods that are especially well suited to low-volume production (1-1,000) of aluminum, magnesium, and zinc castings – a plaster casting method and a sand casting method

Plaster Casting is the process of making cast metal parts using plaster molds as the “die”.

  • A machined pattern is used to make a silicone “tool”. The tools are usually made in two halves. (A tool to produce a core is also sometimes required.)
  • Plaster is poured into the tool halves (and the core, if required) and allowed to harden
  • The hardened plaster halves (and the core) are dried and assembled (or assembled and dried) to form a plaster mold
  • Molten metal is poured into the assembled plaster mold
  • After it cools, the plaster is broken away from the metal and the casting (with rigging) remains

Benefits:

  • Tooling timing is much faster than die cast tooling timing (1-2 weeks vs. 10-20 weeks)
  • Tooling cost much less than die casting
  • High detail, fine features, and very thin walls are possible
  • Parts can be cast with zero draft
  • Quality finish

Sand Casting is the process of making cast metal parts using sand molds.

Basic Sand Casting process (for more information, see our Sand Casting Process page):

  • Sand is molded around a pattern or packed over a “match plate” to create two mold halves
  • Molten metal is poured into the cavity created between the two mold halves
  • After the metal cools, the sand is broken away from the metal and the casting (with rigging) remains

Benefits:

  • Very short tooling lead time
  • Tooling is less expensive than plaster casting and much less than die casting
  • Excellent mechanical properties