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      Baldwin Manufacturing Metal Casting Comparison Matrix


Note: The values listed below are for comparison only and are not absolutes.

Each project and each manufacturer is different. Therefore, these values will vary.
 “~” = approximate                                                                                                                                                                                                              


Typical Process

Investment Lost Foam Castings

Investment (Lost Wax) Castings

Precision Sand Casting

Rubber Plaster Molding

Die Casting

Powder Metal Parts

Permanent Mold

Metal

Injection Molding

Machining Processes

Pricing: Tooling (N.R.E.) and Parts

Tooling: $2.5K - 8K

 

Parts: $High avg.

Tooling $3K – 10K

Parts: $ High

Tooling $800 - 4K

 

Parts: $Average

Tooling $1K– 10K

 

Parts: $ High

Tooling $10K- 100K

 

Parts: $Lowest

Tooling $2.5K – 8K

 

Parts: $Lowest

Tooling $3K – 15K

 

Parts: $Low avg.

Tooling $10K - 30K

 

Parts: $Low avg.

Tooling $800 – 1.5K

 

Parts: $Highest

Quantities, Typical

200 - 2000

1 and up

Under 1000

10 - 1000

2000+

5000+

300+

5000+

Under 100

Tolerances

 Average

Above Average

Below Average

Above Average

Above Average

High

Above Average

High

Highest

Metal Options

Aluminum, Zinc & ZA

All metals except Tungsten

Aluminum, Zinc & ZA

Aluminum, Zinc & ZA

Aluminum, Magnesium, Zinc & ZA

Many Alloys & soft magnetics

Aluminum, Zinc & ZA

 

Many Alloys & Ceramics

All Materials

Design Freedom

 

Average

 

 

Most

 

Average

 

Above Average

 

Least

 

Above Average

 Average

Above Average

Most

 

Size Ranges Maximum

Up to 10 lbs.

Up to 100 lbs.

Up to 100 lbs.

Up to 25 lbs.

Up to 30 lbs.

Up to 0.5 lbs.

 

Up to 100 lbs.

Up to 0.5 lbs

All

Draft Required

Yes

No

Yes

No

Yes

No

Yes

No

 

No

Surface Finish, Typical

90 - 125 RMS

63 – 125 RMS

200 – 250

 RMS

63 – 125

RMS

 

 

 

 63 RMS

~20 RMS

90 – 125 RMS

 

~32 RMS

 

 

32 RMS

Wall Thickness, Typical (min.)

 

.100”

.060”

.140”

.060”

.045”

~.005”

~.140”

~.005”

Under .010”

Normal Delivery Times: 1st Article

Production

 

3 to 6 Weeks

 

3 to 6 Weeks

 

1 to 4 Weeks

 

1 to 5 Weeks

 

1 to 4 Weeks

 

1 to 5 Weeks

 1 to 4 Weeks

 

1 to 5 Weeks

 

10 to 16 Weeks

 

1 to 5 Weeks

 

3 to 6 Weeks

 

3 to 6 Weeks

 

3 to 6 Weeks

 

2 to 5 Weeks

 

 

4 to 6 Weeks

 

4 to 6 Weeks

 

1 to 2 Weeks

 

1 to 2 Weeks

Advantages

 

Great finish, tolerances and with low cost tooling and tooling changes

The most design and metal options.

Least expensive

tooling with

reasonable part

prices.

Good die cast prototype. Great finish and design options. Low cost tooling and tooling changes.

Great finish, tolerances and piece prices

The most Design and Metal Options. Great finish, tolerances and piece prices

Structurally stronger metallurgy. Less piece price than sand casting

The most design and metal density. great finish, tolerances and piece prices

The most design and metal options. Thinnest walls and best surface finish.

Disadvantages

 

Limited Design options, metals and metal integrity.

High part price and limited size

Rough finish, tolerances and thick walls. Limited metal options.

High part price and limited metal options

Limited design options, metals and sizes. Expensive tooling

Larger quantities and limited size

More expensive tooling than sand casting

Tooling and Material Cost. High minimum quantities

Very high part price and limited quantities with time

More Information Links

Investment Lost Foam Castings Information

Investment Casting Information

Precision Sand Casting Information

Rubber Plaster Mold Information

 

Die Casting Information

Powder Metal Information

Permanent Mold Information

Metal
Injection Molding
Information

 

Machining Information


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