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We'll go over a brief overview of each process and then make comparisons between them.

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Sandcasting uses a sand-based mold to shape molten metal.

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It is used to produce a broad range of parts from small jewelry items to large industrial components.

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Diecasting is a manufacturing technique in which molten metal is injected into a reusable steel die under high pressure.

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It is commonly employed for high-volume production in industries such as automotive, aerospace, and consumer electronics.

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Investment casting involves forming a wax pattern, encasing it in a ceramic shell, melting out the wax, and then pouring molten metal into the cavity.

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It is often used for high-performance alloyed parts such as aerospace turbine blades and medical implants.

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A pattern is a replica of the desired part geometry used to create the mold.

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Sandcasting uses an expendable silica-based sand mold made from a reusable pattern.

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Diecasting uses a durable metal die, typically machined from a digital model, so no pattern is needed.

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Investment casting uses an expendable ceramic mold created from a one-time wax pattern.

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The production rate of each process varies.

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For sand and investment casting, because tools need to be re-created for each part, they are capable of lower production volumes.

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For diecasting, once the die is made, parts can be manufactured rapidly, so it is suitable for higher production volumes.

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Sandcasting has the lowest initial cost since the pattern is reusable, and sand molds are inexpensive to make.

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The process is simple, so part-cost are medium.

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Diecasting has the highest initial cost, as the die needs to be machined very precisely.

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Parts are made quickly and cheaply.

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Lastly, investment casting requires dies to be made for wax patterns, but they are cheaper than diecasting.

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Production is labor-intensive and slow, resulting in the highest part cost.

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Sandcasting can make simple to decently complex shapes, but cannot capture fine or intricate details.

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Diecasting can produce complex shapes with high precision, but have limitations in areas such as wall thickness and overhanging geometry.

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Investment casting can create highly complex and intricate shapes.

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Sandcasting is the most versatile in terms of size and is suitable for large parts.

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Diecasting is limited to medium-sized parts, while investment casting is limited to smaller parts.

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Sandcasting and investment casting can be used for a broad range of metals, including ferrous and non-ferrous metals.

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Meanwhile, diecasting is primarily used for non-ferrous metals like aluminum, zinc, and copper alloys, due to their lower melting points.

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Sandcasting produces rougher surface finishes and often requires a secondary process.

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Diecasting produces shapes with smoother finishes, and investment casting produces shapes with very smooth surface finishes.

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Sandcasting has lower tolerances and requires a greater machining allowance.

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Diecasting is used for very high tight tolerances, while investment casting is used for extremely tight tolerances.

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To summarize, sandcasting is best for large, simple parts where cost is a primary concern, design changes may be needed, and a rougher finish is acceptable.

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Diecasting is optimal for mass-producing high volumes of small or medium-sized complex parts using non-ferrous metals.

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Investment casting is ideal for intricate high precision parts.

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Thank you for watching!

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To learn more about the different manufacturing processes, please check out the CustomPartNet website.