Casting Matrix
Compare casting technologies — analyze tolerances, materials, and cost efficiency for optimal process selection.
The EDS Casting Matrix provides a side-by-side comparison of the main casting processes applied in modern manufacturing. It helps engineers and buyers evaluate parameters such as dimensional tolerances, surface finish, material compatibility, production cost, and process limitations.
Technical Comparison Table
| Property | Sand Casting | Investment Casting (Water Glass) | Investment Casting (Silica Sol) | Shell Moulding | Gravity Die Casting | High Pressure Die Casting | Lost Foam Casting | Sintering |
|---|---|---|---|---|---|---|---|---|
| Metals | Ferrous & Non-Ferrous | Most Ferrous | Most Ferrous | Most Ferrous | Only Non-Ferrous | Only Non-Ferrous | Most Ferrous | Ferrous & Non-Ferrous |
| Size of Components | All sizes | Small–Medium | Small–Medium | Small–Medium | Small–Large | Small–Medium | Medium | Very Small |
| Weight (kg) | 0.01 – Many tonnes | 0.01 – 20 (max 50) | 0.01 – 10 (max 50) | 0.01 – 10+ | 0.01 – 75 (max 300) | 0.01 – 10 (max 40) | 1 – 200 | 0.05 – 1 |
| Design Flexibility | High | Very High | High | High | Moderate | Relatively High | High | Moderate |
| Production Unit (pcs) | 1 – 1000 | 10 – 500 | 10 – 500 | 100+ | 1000+ | 10,000+ | 500 – 1000 | 10,000+ |
| Tooling Cost | $ | $ | $ | $$ | $$ | $$$ | $$$ | $$$$ |
| Secondary Machining | High | Moderate | Low | Low | Moderate | Very Low | Low | None |
| Manufacture Cost | Low | Low | Medium | Medium | Low | Medium | Medium/High | Very High |
| Dimensional Tolerance (ISO 8062) | CT10–CT12 | CT7–CT9 | CT4–CT6 | CT7–CT8 | CT7–CT8 | CT4–CT5 | CT7–CT8 | CT1–CT2 |
| Min. Wall Thickness (mm) | 6 – 8 | 4 – 5 | 2 | 5 | 4 | 2.5 | 3 | 3 – 4 |
| Draft Angle (°) | ±2.0° | ±1.0° | ±0.5° | ±1.0° | ±1.0° | ±0.5° | ±1.5° | ±0.1° |
| Surface Finish (Ra µm) | Ra 50 | Ra 25 | Ra 3.2 | Ra 25 | Ra 12.5 | Ra 3.2 | Ra 25 | Ra 3.2 |
Note: Some values estimated based on internal expertise and industry benchmarks when official data was unavailable.
Dimensional Accuracy & Minimum Wall Thickness Comparison
This chart illustrates the balance between process precision (ISO 8062 CT) and minimum cast wall thickness.
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