I want advice on what processes are best suited to my component
Getting it right
At MRT Castings we want to ensure that we provide you with the right solution, tailored to your requirements. Not only do we have a range of casting processes available but we can provide you with advice and guidance based on years of industry experience. Take a look at our Castings Chart below and we can then discuss your requirements further.
Which is the right casting process for me?
High Pressure
Die Casting
High Pressure Die Casting provides the shortest route from molten metal to completed component. Molten aluminium or zinc alloy is injected into a hardened tool steel mould and allowed to solidify under pressure before ejection.
Tooling
Hardened tool steel moulds. Relatively expensive tooling, but pays back in lower unit costs.
Volumes
The most economic method for high volume production, typically demand of 2,000 to 500,000 per annum.
Wall Thickness
Min. Wall Thickness 1-2mm.
Surface Finish
Excellent Surface Finish. No trimming required apart from to remove in-gates.
Accuracy
Highest dimensional accuracy.
Gravity
Die Casting
Gravity Die Casting employs cast iron moulds which allow aluminium and zinc castings to be produced more accurately and cheaply than with sand casting. Rapid chilling gives excellent mechanical properties whilst non-turbulent filling ensures production of heat treatable gravity castings with minimal porosity.
Cast Iron or Steel Moulds. Moderate tool and unit costs.
Suits demand of 250 to 50,000 per annum.
Min. Wall Thickness 3-4mm.
Good Surface Finish, but with slight texture due to die coatings.
Moderate dimensional accuracy
Sand
Casting
Sand casting offers the simplest medium for production of non ferrous castings, by pouring molten zinc, aluminium or copper alloys into a sand mould.
Wooden or Resin Patterns. Lowest Tooling cost, but higher unit production costs.
Ideal for prototypes and small volume production, of 1 to 500 per annum.
Min. Wall Thickness 3-5mm.
Fair Surface Finish. Parts will generally be shotblast to improve appearance after removal from the mould.
Least accurate process
I WANT TO RECEIVE ... ADVICE ON WHAT PROCESSES ARE BEST SUITED TO MY COMPONENT
Please fill in your details below and we will contact you as soon as possible to discuss your requirements
HOW can MRT Castings help you?
I want...
- Select what you need
- a complete solution
- to develop a new component from initial concept
- advice on what processes are best suited to my component
- prototypes before committing to production tooling
- to re-shore production to the UK from overseas
- a new supplier to use existing tooling
- to convert a machined from solid part to a casting
- a supplier who can meet stringent quality requirements
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