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<p>Wherever you are in the world, whatever you need from your precision die cast components, we can help. Contact us on <a href="tel:+18443550631">844.355.0631</a> for assistance or enquiries.</p>

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<h2>What is the difference between die casting and investment casting?</h2><p>Casting is one of the oldest manufacturing techniques, dating back to 1838. While the basic casting process has not changed significantly, today’s machines are more advanced and technological improvements offer several ways to produce your finished product or component. Two common and very similar processes are die casting and investment casting. Read on as we discuss the differences between the processes and explain their respective advantages and disadvantages, helping you select the right process for your next project.</p><h2>The die casting process</h2><p>Simply put, when die casting a component, molten metal is injected into a hardened steel die cavity. Once the metal solidifies, it is ejected from the tool and the process is repeated. The process varies slightly depending on the material selected—see <a href="/die-casting-technologies/hot-chamber-die-casting" target="_self">hot chamber die casting</a> and <a href="/die-casting-technologies/cold-chamber-die-casting" target="_self">cold chamber die casting</a>. The hardened steel mould can produce anywhere from 150,000 shots to over a million shots before requiring repair or replacement.</p><h2>The investment casting process</h2><p>Creating a component using the investment casting or “lost wax” process is typically more time-consuming. A wax prototype of the component is produced and repeatedly dipped into liquid ceramic. The ceramic hardens, then the wax is melted out, leaving a ceramic mould. Molten metal is then poured into the ceramic cavity formerly occupied by the wax. Once the metal solidifies, the ceramic mould is broken and removed, leaving the metal casting. The mould used to create the wax pattern can be used many times; however, the ceramic mould is broken and discarded with each component. Signicast has automated every aspect of the investment casting process, making one-week lead times possible, compared with an industry average of 8-16 weeks. </p><h2>Which process is right for my project?</h2><p>No two casting projects are the same, and different projects require different solutions. Here are a few factors to consider before starting your next project, to help you select the right process for your component.</p><h3>Material selection</h3><p>Most die cast components are made from non-ferrous metals such as zinc, aluminium and magnesium. Investment casting can cast these metals as well as ferrous metals, including stainless steel. If you wish to use a non-ferrous material, both processes offer comparable features. However, if you require stainless steels or copper alloys, investment casting is the better option.</p><h3>Annual volume</h3><p>When deciding which casting process to use, consider your desired payback period for tooling costs. How many components must be produced against the cost of the tooling to “break even”? While investment casting tooling may be less expensive and suitable for lower-volume projects, die casting is ideal for larger production runs and high-volume projects.</p><h3>Tolerance</h3><p>With any casting process, tolerance capabilities are largely influenced by the shape of the component and the type of material used. The table below compares general linear tolerances for conventional die casting and investment casting. The Multi-Slide die casting process can achieve even tighter tolerances.</p><table><tbody><tr><td>&nbsp;</td></tr><tr><td><strong>Dimensional tolerance comparison</strong></td><td>&nbsp;</td><td>&nbsp;</td></tr><tr><td>&nbsp;</td><td><strong>Die casting</strong></td><td><strong>Investment casting</strong></td></tr><tr><td><strong>Up to 25mm</strong></td><td><strong>+/- 0.050mm</strong></td><td><strong>+/- 0.250mm</strong></td></tr><tr><td><strong>Up to 50mm</strong></td><td><strong>+/- 0.075mm</strong></td><td><strong>+/- 0.350mm</strong></td></tr><tr><td><strong>Up to 75mm</strong></td><td><strong>+/- .0.100mm</strong></td><td><strong>+/- 0.400mm</strong></td></tr><tr><td><strong>Up to 100mm</strong></td><td><strong>+/- 0.125mm</strong></td><td><strong>+/- 0.500mm</strong></td></tr><tr><td><strong>**Please allow up to 0.025mm for each additional 25mm</strong></td><td>&nbsp;</td><td>&nbsp;</td></tr></tbody></table><h3>Cycle time</h3><p>While investment casting and die casting both produce complex components, their cycle times differ greatly. Traditional investment casting is a time-consuming process requiring considerable labour and working hours, whereas die casting can produce 3-4 shots per minute for <a href="/die-casting-technologies/conventional-die-casting" target="_self">conventional die casting</a> and upwards of 45 shots per minute with <a href="/die-casting-technologies/multi-slide" target="_self">multi-slide die casting</a>. A die cast component can often be produced without human intervention—complete automation! </p><h3>Cost</h3><p>Cycle time determines up to 60% of your final component cost, so it is no surprise that, per component, investment casting generally costs more than die casting. Its highly manual processes produce components very similar to die castings, but the cycle time is much longer. </p><p><strong>For high-volume casting, die casting is more cost-effective than investment casting. If you are casting only a few components or require larger sizes or stainless steel, investment casting may be the lower-cost option.</strong></p><p>While both investment casting and die casting produce components with comparable features, where extremely high-volume manufacturing is required, the associated costs and longer cycle times can make investment casting a less suitable option, depending on your requirements and deadlines. It is best to speak with an experienced casting engineer to determine which casting process is most suitable for your next project—contact our team today!</p>

Ladel of metal for the cold chamber die casting process

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Understand the key differences between die casting and investment casting, and select the right process for your component design and production requirements.

Die casting vs. investment casting | key differences

Die casting and investment casting are two common casting methods. The choice depends on factors such as material, volume, tolerance, speed and cost. 

Die casting vs. investment casting

<h2>Discover the benefits of die casting</h2><p>Are you new to precision die casting or a veteran with years of expertise? Staying ahead when it comes to precision die casting is essential. Learn why die casting is often more cost-efficient than other manufacturing processes, offering not only part price savings, but also major reductions in overall production costs! </p><p>With die casting, you can create complex net shapes, including complex internal and external features with minimal draft angles, minimising secondary operations. <strong>This webinar aims to guide our customers on how to take advantage of the benefits of die casting.</strong></p><p>Join us as the Dynacast Europe team presents <em>Discover the benefits of die casting</em>. In this webinar, our team will cover:</p><ul><li><a href="/die-casting-technologies" target="_self">Die casting technologies</a></li><li><a href="/metals" target="_self">Die casting metals</a></li><li><a href="/additional-capabilities/engineering" target="_self">Design capabilities</a></li><li><a href="/resources?type=caseStudies" target="_self">Case studies</a></li><li>And more!</li></ul><p><strong>Die casting unpacked</strong></p><p><strong>When:</strong> On-demand</p><p><strong>Where:</strong> Online – join from anywhere!</p><p><strong>Presenters:</strong> Christian Flich, Sergio Perino, Bernd Froehlich</p><p><em>** The webinar is presented in English.**</em></p><p><em></em></p><p><strong>Complete the form to watch our free webinar on demand.</strong></p><p>&nbsp;</p>

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Explore the fundamentals of die casting, from material flow to cooling and ejection, in this clear introductory overview for new engineers and designers.

Die casting process explained | Dynacast

Explore the cost-efficiency and design flexibility of precision die casting with Dynacast Europe’s expert team in our on-demand webinar 

Die casting unpacked

<p>Die casting is a manufacturing process that uses high-pressure molten metal to create intricate metal parts. It is a versatile process that can be used to produce a wide variety of parts, including automotive components, electronics housings and medical devices.</p><p>While die casting is a reliable process, it can sometimes produce defects. This article discusses some of the most common die casting defects, their causes and solutions.</p><h2>Die casting defects</h2><p>When <a href="/metals/zinc" target="_self">zinc die casting</a> first became available, it quickly gained recognition as a lightweight and cost-effective alternative to other alloys such as tin and lead. Over the past century, zinc alloys have made steady progress. While zinc has always been recognised for its high strength, the introduction of the Zamak family, and now the revolutionary EZAC™ alloy, has further enhanced the suitability of zinc alloys for hot-chamber die casting across a wide range of applications. Prior to the introduction of EZAC™, zinc was often overlooked for applications requiring high tensile strength, especially at high temperatures. Additionally, most zinc alloys exhibited low creep resistance compared with other materials. These areas for improvement were the primary focus during the creation of EZAC™, resulting in a zinc alloy that surpasses previous limitations.</p><h3>Heat checks</h3><p>Heat checking is localised cracking or surface damage that can occur on the die casting mould. It is caused by thermal stress and cycling, which can be exacerbated by factors such as inadequate cooling, excessive overspray or thick mould sections.</p><h3>Soldering</h3><p>Soldering is the formation of a thin metal layer on the casting surface. It is caused by erosion or dissolution of the die material due to uneven cooling, localised high temperatures or improper metal flow. Soldering can be prevented by improving cooling, <a href="/additional-capabilities/part-improvement" target="_self">optimising part design</a>, and improving metal flow management.</p><h3>Cracks</h3><p>Cracks are fractures or separations that can occur in the die casting. They can be caused by stress concentration, rapid cooling and uneven thermal gradients. Cracks can be minimised by evaluating casting geometry, adjusting process timing and enhancing thermal management.</p><h3>Dimensional issues</h3><p>Dimensional issues involve deviations from the required dimensions and tolerances in the die-cast part. They can be caused by unrealistic drawing tolerances, variations in process parameters and thermal expansion effects. Dimensional issues can be minimised by optimising tolerances, controlling process parameters and considering thermal effects.</p><h3>Flash</h3><p>Flash is excess material that escapes between mould halves, forming thin fins or flanges on the casting. It can be caused by insufficient machine tonnage, die wear or misalignment, and suboptimal process parameters. Flash can be prevented by ensuring adequate machine tonnage, carrying out regular die maintenance and optimising process parameters.</p><h3>Shrinkage porosity</h3><p>Shrinkage porosity is characterised by voids or cavities formed due to the shrinkage of molten metal during solidification. It can be caused by non-uniform wall thickness and abrupt section transitions in the part design. Shrinkage porosity can be minimised by optimising casting geometry and implementing effective thermal management.</p><h3>Flow marks (cold flow, non-fill, etc.)</h3><p>Flow marks appear as visible lines or streaks on the casting surface due to the flow of molten metal during mould filling. They can be caused by flaws in part geometry and inadequate gate and runner design. Flow marks can be minimised by refining part geometry, using flow simulation software and implementing real-time monitoring.</p><p>A comprehensive understanding of common die casting defects, their causes and practical solutions is pivotal to <a href="/additional-capabilities/engineering" target="_self">engineering high-quality castings</a>. By implementing the solutions discussed in this article, manufacturers can effectively address defects, improve production efficiency and deliver products that meet exacting quality standards.</p>

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Learn about the 8 most common die casting defects, their causes and proven methods to prevent or resolve heat checks, cracks, porosity, flash and flow marks.

Die casting defects: causes and solutions | Dynacast

See eight common die casting defects, including heat checks, gas porosity and soldering, with insight into their causes and practical solutions to improve production quality and efficiency. 

Precision inevery cast

Engineered excellence in
die casting

Innovation that drives
performance

Exclusive technologies foradvanced die-casting solutions

Unlock potential with the right metal

Aluminium die casting

Magnesium die casting

Zinc die casting

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Beyond the basics

Die-casting resources

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Interested in starting your die casting project?

Precision inevery cast

Engineered excellence indie casting

Innovation that drivesperformance

Exclusive technologies foradvanced die-casting solutions

Unlock potential with the right metal

Aluminium die casting

Magnesium die casting

Zinc die casting

Global reach,local support

Beyond the basics

Die-casting resources

Article

Webinar

Article

Interested in starting your die casting project?

Engineered excellence in
die casting

Innovation that drives
performance