Pressure Die Casting Aluminum Lighting Parts vs Sand Casting. Aluminum sand cast tooling roughly costs from $500 – $7,500, depending on the size and complexity. Pressure die cast tooling on the other hand costs from $5,000 – $75,000, again depending on the size and complexity of the die cast parts. However, tooling can create from 100,000 parts to as much as 1,000,000 pressure die casting parts.
In sand casting, the moulds or patterns are used to make sand moulds. The preparation and bonding process of sand moulds is the most critical step in the process. This technique is usually used for high volume production.
With die casting, the mould is usually made of metal like cast iron or steel. They are generally not destroyed but are made permanent. There are several types of die casting, the most widely used being high pressure die casting. 50% of light alloy casting production are made from high pressure die casting.
Sand casting and pressure die casting processes vary from some hundred to some thousand parts. The cost of tooling and machinery is required for aluminum sand casting that is not normally required in the die casting process due to its tighter tolerance of the pressure die cast process in making the aluminum parts.
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