Which is the right casting process for me?
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.
Hardened tool steel moulds. Relatively expensive tooling, but pays back in lower unit costs.
The most economic method for high volume production, typically demand of 2,000 to 500,000 per annum.
Min. Wall Thickness 1-2mm.
Excellent Surface Finish. No trimming required apart from to remove in-gates.
Highest dimensional accuracy.
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 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
Take a look at how we work
Find out more information about MRT Castings and get a taste of our facilities.
Check out our virtual tour and find out how we can work with you on your next project.
HOW can MRT Castings help you?
- 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
New at MRT
5th Dec 2018
MRT Castings is delighted to announce the purchase of a new PFO250 fully automated, die casting cell, from Italian manufacturer Colosio.Read More
Visit us at stand C195 at the Farnborough Internaltional Exhibition & Conference Centre on 5th, 6th & 7th February 2019.Read More
31st May 2018
Around 6 months ago, we took a hard look at how we use the data we have available to us at MRT Castings. We looked at everything from data being used by machines, data being created by machines all the way through to where data is being left on the cutting room floor and where data can potentially be corrupted or lost through human error.Read More