Ramsden Industries Limited
Phone:519.451.6720

 

  SAND CASTING PERMANENT MOLD CASTING DIE CASTING
Description Tempered sand is packed onto wood or metal pattern halves, removed from pattern, assembled with or without cores, and metal is poured into resultant cavities.  Various core materials can be used.  Molds broken to remove castings.  Specialized Binders now in use can improve tolerances and surface finish.
    
Molten metal is gravity poured into cast iron molds, coated with ceramic mold wash.  Cores can be metal, sand, sand shell or other.  Molds open and castings ejected.  New L.P.P.M. method pressure-pours with up to 15 psi.
   
Molten metal is injected, under pressure, into hardened steel dies, often water cooled.  Dies open and castings ejected.
    
Metals Most all castable metals.
   
Aluminum, Zinc, some Brass, Bronze, Lead, and Gray Iron.
  
Aluminum, Zinc, Magnesium and limited Brass.
  
Size Range Limitation mainly foundry capabilities.  Ounces to many tons.
   
Limitation mainly foundry capabilities.  Aluminum and copper base: ounces to 100 lbs. Ferrous: 60 lbs. max.
   
Not normally over 2 feet square.  Some foundries capable of larger sizes.
   
Tolerances Non-Ferrous: +/- 1/32" to 6".  Add +/- .003* for each additional inch.  Ferrous: +/- 1/32" to 3" +/- 3/64" from 3" to 6". Across parting line add +/- .020" to +/- .090" depending on size (Assumes Metal Patterns).
   
Aluminum: Basic +/- .015.  Add +/- .002"/in.  If across parting line add +/- .010" to +/- .030" depending on size.  Copper Base: Similar to investment.  Iron +/- .03" Basic.
   
Al and Mg +/- .002"/in.
Zinc +/- .0015"/in.
Brass +/- .005"/in.
Add +/- .001" to +/- .015" across parting line depending on size.
   
+ Tooling Cost Wood: 5
Aluminum: 4
Iron: 2
   
2 1
+ Part Price 3-4 Non-Ferrous: 3-4
Ferrous: 4
   
5
+ Design Freedom 2 Non-Ferrous: 3
Ferrous: 5
   
4
Minimum Draft Requirements 1 to 5
Cores: 1 to 1-1/2
  
Non-Ferrous:
Outside: 2
Min. (3 desirable)
 
Al & Mg: 1 to 3
Zinc: 1/2 to 2
Brass: 2 to 5
  
++ Normal Minimum Section Thickness Non-ferrous: 1/8" to 1/4"
Ferrous: 1/4" to 3/8"
Aluminum: .100" for small areas, up to 3/16" or more for large areas.
Copper Base: .060"
Ferrous: 3/16" for small areas, 1/4" normal.
 
Al: .03" small parts, .06" medium parts
Mg: .03 Small parts
Zinc: .025" Small parts
.040" medium parts
 
Ordering Quantities All quantities Minimum One Day's run: (100-1000), depending on size
  
Usually 2,500 and up
 
+++ Normal Lead Time Samples: 2-10 weeks
Production: 2-4 weeks A.S.A.
 
Samples: 8-20 weeks
Production: 4-8 weeks A.S.A.
 
Samples: 12-22 weeks
Production: 8-10 weeks A.S.A.
  
+ 1 = Most    5 = Least
 
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