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Casting is a Primary molding process. The basic process is always the same:

1. A material (e.g. metal, plastic) is liquefied (usually by melting).
2. This melt is poured into a cavity, the so-called Shape (also known as a die or mold), cast or injected.
3. The material cools in the mold and solidified, It takes on the exact inner contour (geometry) of the mold.
4. The finished component (cast part) is removed from the mold (demolded).

The difference is fundamental:

• Giessen (casting): Works with liquid Material. The metal is melted and fills a mold. The result has a cast structure, is often more brittle, but can take on extremely complex shapes.
• Forging: Works with solid, but heated material. A solid block of metal (blank) is forced into shape by hammering or pressing. 

This compacts the material structure (fiber flow). Forged parts are therefore extremely tough, strong and durable (e.g. wrenches, crankshafts), but geometrically more limited than cast parts.

Both are casting processes, but with fundamentally different approaches and forms:

• Die casting (Die Casting):
  • Shape: Uses an expensive, durable Steel permanent mold (mold), which is reused thousands of times.
  • ProcessThe molten metal usually consists of non-ferrous metals. These include aluminum, zinc or magnesium. 

This melt is shot into the mold at high pressure. The pressure can be up to 1,000 bar. The speed is also high.

• Result: Very fast (short cycle times), extremely precise, smooth surfaces. Ideal for High quantities (series production).

• Investment casting (investment casting / lost wax process):
  • Shape: Uses a „lost form“ made of ceramic. This is created anew for each individual part and destroyed at the end.
  • Process: A model of the part is created from wax. This wax model is dipped in ceramic slip until a thick ceramic shell is formed. The shell is heated and the wax melts out (hence the „lost wax process“). The empty ceramic mold is then cast with metal (all metals are possible, including steel and titanium).

Result: Slow process, but unsurpassed in the geometric freedom (most complex parts, undercuts) and variety of materials.

This is a watering principle in which the mold is used only once. It must be destroyed in order to remove the casting.

The advantage is that complex geometries with undercuts can be cast. As a rule, these would not be obtained from a rigid permanent mold (as with die casting).

The two best-known procedures are

1. Investment casting (The ceramic bowl is broken).
2. Sand casting (The mold made of pressed sand is broken after casting).

The tolerances are extremely dependent on the process. As a rule of thumb (very rough):

• Sand casting (most inaccurate): Often +/- 1 mm per 100 mm or more.
• Investment casting (very precise): Approx. +/- 0.1 mm to +/- 0.4 mm.
• Die casting (most accurate): Very precise, often +/- 0.02 mm to +/- 0.1 mm (especially zinc die casting).

Important: Critical dimensions (e.g. bearing fits, sealing surfaces) are almost always subsequently mechanically processed (milled, turned) in order to achieve CNC precision. Tolerances are also maintained for mold construction/toolmaking to ensure optimum series production.

This depends on the casting process:

• Die casting: Almost exclusively non-ferrous metals (NF metals) with a lower melting point:
  • Aluminum alloys (AlSi, AlMg)
  • Zinc alloys (Zamak)
  • Magnesium alloys
• Investment casting & sand casting: Almost all metals can be cast:
  • Ferrous metals (cast steel, cast stainless steel, cast iron)
  • Copper alloys (bronze, brass)
  • Aluminum alloys
  • Titanium and nickel-based superalloys (investment casting only)
• (injection molding as a related process):
  • Thermoplastics (ABS, PA, PC, POM, PEEK etc.)

• High tooling costs: The steel molds (tools) are extremely expensive, especially for die casting and injection molding. The process is often only worthwhile from thousands of pieces.
• Casting defects: Defects can occur in the material structure (blowholes, porosity, inclusions). These are small cavities or impurities that can reduce the strength.
• Lower strength: Cast parts are often not as strong and robust as parts that are forged or milled from a solid block.
• Limited prototypes: (See next question).

This is a critical point. For Series die casting (aluminum, zinc) are available none economical casting prototyping, as the steel mold is too expensive.

Prototypes for later cast parts are therefore usually simulated:

• CNC milling: The part is milled from a solid block (e.g. aluminum). This is ideal for testing the function with the final material.
• 3D printing (metal or plastic): Ideal for quickly checking the shape, fit and ergonomics (fit check).

Real cast prototypes (if the casting structure needs to be tested):

• Investment casting or Sand casting can be used for prototypes, as mold production (wax model or sand mold) is cheaper.

Clearly: Investment casting (lost wax process).

The wax master model can be molded into very complex shapes. It can even be 3D-printed. The ceramic mold is built around the model. The mold is later destroyed. There are therefore almost no geometric limits. Internal channels, undercuts and filigree structures are possible. Ask the team directly.

All of the casting processes mentioned above can handle complexity. However, the choice depends heavily on the material (plastic vs. metal), the required quantity and the specific requirements (e.g. how thin-walled, whether bubble-free, or whether it is primarily about internal contours).

Cast iron is the classic in Mechanical engineering and Plant engineering.

Its greatest advantage is the excellent Vibration damping (the carbon in the structure „swallows“ vibrations) and the high Compressive strength.

• Machine beds & frames: (e.g. for CNC milling machines, lathes), as it is heavy and dampens vibrations, which increases precision.
• Automotive industry: (e.g. engine blocks, brake disks, gearbox housings).
• Fittings & pumps: (housings for pumps and valves).
• Heavy-duty components: (e.g. foundation plates, weights).

Casting processes are one of FACTUREE's core competencies. Go to the quotation page and upload your CAD file. The process is easy and intuitive. You can of course also send us an email to anfrage@facturee or get in touch directly with our contact persons Billy Schulz, Antonio Scala and Walid Tlili. 

We then use our AI-supported system to check who is the best manufacturing partner for your cast parts and give you the best possible price.

Online production has become indispensable these days. For cast parts, online production offers numerous advantages: 

• Fast production of customized castings: often with delivery in 9-12 working days.
• High precision for complex geometries
• Cost efficiency for prototypes and series: No tooling costs for casting; low unit prices thanks to smart paver selection.
• Variety of materials for every requirement - everything can be ordered digitally.
• Flexibility with quantities and variants: Individual parts, variant production or mass production - without long lead times.
• Perfect for recurring components: Framework agreements and price stability for series parts or maintenance components
• Seamless integration into digital development processes: Simple upload of DXF, STEP or STP files, automatic checking and quotation generation
• Quality control and ISO certification: Manufacturing partner with proven quality and reliable delivery