I have a new design that I know could be cast in metal cheaper than other processes like stamped steel or machined metal, how can I select a cost effective casting material and process?
Boy, thats a big question we can only offer you suggestions here they are: Do you need extreme strength? Gravity cast iron or steel provides more strength per pound when really high strength is required though often a greater price than die cast. For medium duty to light heavy duty parts consider aluminum gravity cast permanent mold or high pressure die casting. If you are considering aluminum, please consider the manufacturing process closely. The debate between gravity cast permanent mold and high pressure die casting is often a volume consideration. Less dimensional parts or complex internal cores (valves) may favor permanent mold especially in lower volume. Bulky parts in low volume like truck brackets are excellent permanent mold or sand cast products. Close net shape (little machining desired) or tighter tolerance (telecom, electrical enclosure etc.) and higher volumes tend to favor die cast. Prototype and low volume should therefore be die cast if at all possible as would high v
