Die-Cast vs Sand-Cast vs Gravity Selector
Choose between high-pressure die, gravity/permanent mould and sand casting based mainly on your annual volume.
How it decides
High volumes justify die-casting tooling; medium volumes suit gravity/permanent mould; low volumes and large parts favour sand casting.
Process comparison
| Process | Volume | Tooling cost | Strength/finish |
|---|---|---|---|
| Die casting | High (10k+) | High | Thin walls, good finish |
| Gravity / PM | Medium | Medium | Best mechanicals |
| Sand | Low / large | Low | Flexible, larger parts |
Frequently Asked Questions
Die casting vs sand casting — which is cheaper?
Die casting has high tooling cost but low per-part cost, so it wins at high volume; sand casting has low tooling and suits low volume or large parts.
When should I use gravity (permanent mould) casting?
At medium volumes when you want better mechanical properties and surface than sand, with lower tooling than die.
What volume justifies die casting?
Typically several thousand-plus parts per year to amortize the die.
Which process gives the best mechanical properties?
Gravity/permanent-mould and low-pressure casting generally give the best properties; die casting can have porosity that limits heat treatment.
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