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
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HOW can MRT Castings help you?
- 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
New at MRT Blogs
Make UK crowned MRT the winner of the prestigious accolade.Read More
23rd Oct 2020
MRT Castings have been honoured at a major regional manufacturing awards ceremony.Read More