Aluminum Sand Casting Parts Quoted as Aluminum Die Casting Parts
Aluminum Sand Casting Vs Aluminum Die Casting
Aluminum is a unique metal due to its ability to be cast in any of the processes used in casting metals. While there are many methods in casting aluminum, two of the most common methods are die casting and sand casting. Both of these processes have their advantages and disadvantages. So how do you go about determining what process you should use? There are many factors that come into play when it comes to selecting a casting process. The two main factors that come into play are.
Feasibility and Cost Factor
Quality Factors
Comparing these two aluminum casting methods side by side will help you determine which process will be the most beneficial for you.
2.5 Billion dollars worth of aluminum die castings are produced each year in the United States alone. Die Casting consumes almost twice the amount of tonnage of aluminum alloy as all the other casting processes combined. So as you can see its a process which is more commonly preferred.
Aluminum sand cast tooling costs range from $500 - $7,500 depending on the complexity and size of the aluminum casting part life is 5,000 parts.
Aluminum die casting tooling costs range from $5,000 - $70,000 depending on the complexity and size of the aluminum diecast part. While the initial expense is more then sand casting the tooling insert life is 100,000 parts and can be as much as 1,000,000 high pressure diecast parts.
Example 1:
Matt has a sample of his aluminum sand casted product. He is happy with the quality and wants to maintain it. Matt requests a quote for his aluminum sand casting part as a possible aluminum die casting part.
Aluminum Sanding Costs
Matt pays $18 for each aluminum sand casting part and puts about $8 of machining into each aluminum casting part. The cost for his sand cast aluminum part is $26 per part.
The Tooling for Matt's aluminum sand casting costs him $1,400 for the pattern and the tool life, which Matt says is 5,000.
Aluminum Die Casting Costs
The Aluminum Die Cast comparison of the same part is $5.20 each part. With the estimated savings in machine costs of $3.00 each for the aluminum die casted part. The aluminum die casting part is $5.20 plus the remaining $5.00 in machining costs, which brings the total price of each aluminum die cast part to $10.20 per part.
The machining required for his aluminum sand castings are greatly reduced in the aluminum die casting process: 8 holes drilled and the top and bottom surfaces milled.
Die cast tooling inserts for Matt's part costs $20,000 and the tool life is typically over 100,000 aluminum die casting parts and can be as many as 1,000,000 die casting parts when tolerances remain similar to the sand casting tolerances.
Lets compare die cast prices against sand cast prices.
Price Per Aluminum Casting Part - (Machining Included)
Sand Cast - $26 | Die Cast - $10.20
Tooling $1,400 | Tooling $20,000
Sand Casting Costs Vs Northwest Die Casting Costs
Aluminum Castings Quantity Ordered - 1,000 / 5,000 / 10,000 / 50,000
Sand Casting - Qty:1,000 X $26 = $26,000 +Tooling $1,400 = $27,400
Die Casting - Qty:1,000 X $10.20 = $10,200 +Tooling $20,000 = $30,200
SAND CASTING 2,800 in savings
Sand Casting - Qty:5,000 X $26 = $130,000 +Tooling $1,400 = $131,400
Die Casting - Qty:5,000 X $10.20 = $51,000 +Tooling $20,000 = $71,000
DIE CASTING 60,400 in savings
Sand Casting - Qty:10,000 X $26 = $260,000 +Tooling $1,400 = $261,400
Die Casting - Qty:10,000 X $10.20 = $102,000 + Tooling $20,000 = $122,00
DIE CASTING 249,200 in savings
Sand Casting - Qty:50,000 X $26 = $1,300,000 +Tooling $1,400 = $1,301,400
Die Casting - Qty:50,000 X $10.20 = $510,000 +Tooling $20,000 = $530,000
DIE CASTING 771,400 in savings
The break-even point from aluminum die casting and sand casting varies from a few hundred to thousand parts. Usually depends on the tooling and machining required. In other words your decision should be based on the estimated required quantities.
There are many other factors that come in to play. I hope this helps you understand the two methods a little better.
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