|
PROCESS |
DESCRIPTION |
TYPICAL
SIZE
RANGE |
TOLERANCES |
SURFACE
FINISH |
MIMIMUM
DRAFT REEQUIRED |
MINIMUM
SECTION THICKNESS |
TYPICAL
ORDER QUANTITIES |
TYPICAL
TOOLING COSTS |
NOMINAL
LEAD TIMES |
|
V-PROCESS
CASTINGS |
Extremely
fine sand is "vacuum packed" around
pattern halves. The pattern is removed and metal poured into
cavity. The vacuum is released and the casting removed. |
Up to 150
pounds |
±.020" to
6", then add ±.002
inches/inch.
Add ±.020"
across parting line. |
125-l.50
RMS |
None |
.125" |
All |
$3,000-
$6,000 |
Samples 2
to 6 weeks.
Production 2 to 6 weeks after approval. |
|
SAND
CASTINGS |
Treated
sand is molded around a wood or metal
pattern. The mold halves are opened and the pattern removed.
Metal is poured into the cavity. The mold is broken and the
casting removed. |
Ounces to
tons |
± 1/32"
to 6", then add
±.003 inchesfinch.
Add ±.020" to .090"
across the parting line. |
200-550
RMS |
1 to 5
degrees |
1/8" |
All |
$800
$4,000 |
Samples 2
to 6 weeks. Production 2 to 6 weeks after approval. |
|
INVESTMENT
(LOST WAX) |
A metal
mold makes wax replicas. These are joined and surrounded by
an investment material. Wax is melted out and metal is
poured into the resulting cavity. The molds are broken and
the castings removed. |
Ounces to
20 pounds |
±.003" to
1/4"
±.004" to 1/2"
±.005" to 3",
then add ±.003 inches/inch. |
63-125
RMS |
None |
.060" |
Under
1,000 |
$3,000
$10,000 |
Samples
10 weeks. Production 5 to 12 weeks after approval. |
|
PERMANENT MOLD |
Molten
metal is poured into a steel mold. The mold is opened and
the casting is ejected. |
Ounces to
100 pounds |
±.015" to
l", then add ±.002 inches/inch. Add ±.010" to .030" across
the parting line. |
150-300
RMS |
2 to 4
degrees |
3/16" |
500 + |
$5,000 -
$15,000 |
Samples 8
to 20 weeks.
Production 10 to 12 weeks after approval |
|
GRAPHITE
PERMANENT
MOLD |
ZA alloys
poured into a graphite mold. The mold is
automatically opened and casting is removed. No
ceramic wash |
Ounces to
10 pounds |
±.005".
±.002" across parting line. |
25 RMS
or better |
1 to 2
degrees |
.100" |
500 –
15,000
pieces |
$1,500 –
$5,500 |
Tooling 3
to 6 weeks. Production 2 to 4 weeks after approval. Lifetime
tooling. |
|
DIE
CASTING |
Steel
dies, sometimes water cooled, are filled with molten
aluminum. The metal solidifies, the die is opened and the
casting ejected. |
Ounces to
15 pounds |
+.002
inches/inch.
Add ±.015" across
the parting line. |
32-63
RMS |
1 to 3
degrees |
1 .030 to
.060 |
2,500 + |
$5,000 –
$100,000 |
Samples
12 to 22 weeks. Production 8 to 14 weeks after approval. |
|
ALUMINUM
EXTRUSION |
In-house
billet casting - aluminum "hot" extruded through internally
manufactured dies. Include fabricating and finishing. |
.015
pound
per foot
17" circle
size |
±.015" or
better
when needed. |
63-125
RMS |
N/A |
.015
point
per foot |
1M pounds |
$1,000
$4,000 |
Samples 6
to 8 weeks.
Production 4 weeks after approval. |
|
COLD
DRAWING |
Any
"cold" workable or high-temperature alloy. Cold drawn or
rolled through a "series" of dies or rolls to yield ultimate
shape. |
.025" dia.
to 2" |
±.0005"
or better.
Can typically hold ±.001". |
25-63 RMS |
N/A |
1/8" |
No
minimum quantities |
$1,000
$4,000 |
Samples 8
to 10 weeks. Production 6 to 8 weeks after approval. |
|
DEEP
DRAWN |
All
metals, deep drawn, hydroformed or spun. To form cases,
cabinets or cans to customer specifications. Painting,
anodizing or assemble. |
Up to 50"
dia.
blank |
±.015 or
better.
Reviewed on an order by order basis. |
63 RMS
or better |
N/A |
.100" |
500
pieces
or more |
$3,000
$15,000 |
Samples 8
to 10 weeks.
Production 8 to 10 weeks after approval. |
|
PLASTER MOLD |
Casting
plaster and water mixed to make slurry. Slurry poured into
flask holding pattern. Slurry solidifies and forms mold.
Metal is poured into mold. When cooled mold is broken away. |
Ounces to
50 pounds |
+/- .005"
for 2" then add +/- .002 " per inch. Parting line shift +/-
.010. |
63 to 125
RMS |
1/2 to 3
degrees |
.060"
premium .080 average |
1 to 100 |
$3000 to
$6000 |
Samples 2
to 6
weeks. |
