Metal Casting and Molding Comparison Matrix

Wisner Associates Metal Molding Matrix

Ken Wisner	(650) 367-1234 Voice	(650) 367-1230 Fax
Charlie Baldwin	(408) 245-7290 Voice	(408) 404-7290 Fax

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 Back to Wisner Associates

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Typical Process	Graphite Permanent Molding	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	10 - 2000	Under 1000	10 - 2000	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 20 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: 1^st 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	Graphite Permanent Molding 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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