What is the difference between casting and investment casting?

Casting makes things by pouring hot liquid into a mold. Investment casting uses a wax shape and a ceramic shell. It makes metal parts that are very exact and smooth. People pick a method based on how accurate it is, how much it costs, and how hard the part is to make.

Casting works well for simple shapes and lots of pieces.
Investment casting is good for tricky designs and close fits.
New ideas use 3D printing for patterns, better ceramics, and robots. These help make things better and faster.

Key Takeaways

Casting works well for simple shapes and making many parts. Investment casting is better for making parts with lots of detail and accuracy. Investment casting uses a hard process with wax patterns and ceramic molds. This makes surfaces smoother and sizes more exact. Pick a casting method by looking at the material, how many parts you need, and your budget. Investment casting is good for small or medium batches that need high accuracy. Both casting types have good and bad points. Casting saves money when making lots of parts. Investment casting gives better quality for parts with complex shapes. KEMING offers many metals for casting. This helps companies choose the best material for what they need.

Casting Overview

Methods

Casting shapes metal and other stuff in many ways. Each way is good for different sizes and shapes. People pick a method based on what the part will do. Some common ways are:

Sand Casting
Die Casting
Investment Casting
Plaster Casting
Centrifugal Casting
Permanent Mold Casting

In every method, workers pour hot liquid into a mold. The mold gives the part its shape. When it cools and gets hard, they take it out. This lets people make easy or hard shapes.

Materials

People use many materials for casting. The choice depends on what the part needs to do. Some popular metals are:

Aluminum
Zinc
Copper
Ductile Iron
Gray Iron
Steel

These metals have different strengths and weights. Some do not rust easily. Aluminum is light and does not rust much. Steel is very strong and lasts a long time. Some ways, like investment casting, work with many metals.

Uses

Casting is important in many jobs. It helps make parts for machines, cars, and art. The table shows how casting is used in different areas:

Sector	Applications
Transportation	Automotive, aerospace, railway, and shipping components
Heavy Equipment	Construction, farming, and mining machinery parts
Machine Tools	Machining centers, casting equipment, plastic molding machinery
Plant Machinery	Chemical processing, petroleum refining, thermal power generation
Defense	Military vehicles, artillery systems, munitions
Electrical Machinery	Motors, generators, pumps
Municipal Infrastructure	Pipes, joints, valves, fittings
Household Applications	Appliances, kitchen equipment, furniture components
Artistic Applications	Sculptures, decorative furniture, ornamental items

Note: Casting can make big or small parts. This makes it useful for many things.

Investment Casting

Process

Investment casting has many careful steps. First, workers make a wax pattern. They put wax into a metal mold. This makes the shape of the part. Many wax patterns go on a wax rod. This looks like a tree. Workers dip the wax tree in a ceramic liquid. The liquid dries and gets hard. It forms a shell around the wax. Next, they heat the shell. The wax melts and leaves the shell empty. Now, workers pour hot metal into the shell. The metal cools and gets hard. They break the shell to get the metal parts. Workers cut the parts off the metal tree. Each part gets checked for quality. KEMING uses good machines and strong checks. This helps every part meet world standards.

Materials

Investment casting uses many metals. Each metal has special uses. The table shows some metals and what they do:

Material	Properties	Applications
Stainless Steel	Strong, lasts long, does not rust	Gears, medical tools, food equipment
Aluminum Alloy	Light, does not rust	Aerospace, car parts
Carbon Steel	Cheap, strong	Motors, appliances
Super Alloy	Stays strong when hot	Turbine blades, energy equipment
Copper Alloy	Does not rust, wears down slowly	Plumbing, electrical parts
Cast Iron	Tough, handles heat well	Big machines

KEMING has many metals to pick from. They offer stainless steel, aluminum, carbon steel, and super alloys. Their factory can make special parts for many jobs.

Applications

Investment casting makes parts for many fields. The table shows where it is used:

Industry	Applications
Aerospace	Engine parts, turbine blades
Automotive	Engine valves, transmission parts
Medical	Surgical tools, implants
Energy & Industrial	Pump housings, valves
Consumer Electronics	Connectors, device cases

KEMING helps aerospace, car, marine, and medical companies. Their team makes special parts for hard designs and exact needs.

Tip: Investment casting is great for making parts with hard shapes and close fits. KEMING’s skill and tools help customers get strong, good parts.

Casting vs. Investment Casting

Process Comparison

Casting and investment casting both shape metal by pouring it into a mold. But they use different molds and steps. Regular casting uses molds made from sand or metal. These molds can be used many times. In investment casting, workers make a wax pattern for each part. They cover the wax with a ceramic shell. This shell becomes the mold. The ceramic mold is used only once. Workers break it to get the part out.

Casting Method	Mold Type
Investment Casting	Disposable ceramic molds
Other Methods	Reusable molds (metal/sand)

Investment casting uses wax patterns and ceramic molds that are thrown away.
Other casting methods use molds made from sand or metal that can be used again.

Investment casting has more steps. Workers make a new wax pattern and ceramic shell for every part. This lets them make parts with more details. Regular casting is faster for simple parts. The same mold can be used over and over.

Tip: Investment casting is best for parts with tricky shapes and small details. Regular casting works well for big, simple, or lots of parts.

Cost

The cost to make parts depends on the method. Investment casting costs more at the start. Workers must make new patterns and ceramic molds for each part. It also takes more time and skill. But investment casting can save money later. The parts come out smoother and more exact.

	Investment Casting	Sand Casting
Upfront Tooling Cost	Medium to High	Medium
Tooling Maintenance	Low	Low to Medium
Cost to Change Design	High	Low to Medium
Post-Cast Machining	Low	Low to Medium
Total Labor Costs	Medium to High	Medium
Total Lead Time	Long	Medium
Best Run Size	Medium to Long	Low to Medium

Investment casting is better for small or medium batches. It is good when the part must be very exact. Sand casting is better for big, simple parts. It is also good if the design might change.

Precision

Precision means how close the part is to the right size and shape. Investment casting gives a smoother surface and tighter fit than regular casting. This means the parts need less extra work after casting.

Casting Method	Surface Finish (Ra)	Tolerances (inches)	Machining Required
Investment Casting	125	.005/inch	Low
Sand Casting	250	Cannot hold tight tolerances	Extensive machining needed

Investment casting can make parts with tiny details and smooth surfaces. Sand casting leaves a rougher finish and cannot hold tight sizes. Workers often need to machine the parts after.

Application Suitability

Picking between casting and investment casting depends on what the part does and how many are needed.

Use investment casting for:
- Parts that need to be very exact
- Hard shapes or thin walls
- Smooth surfaces
- Small or medium batches
- Both ferrous and non-ferrous metals
- Jobs like power plants, cars, and planes
Use sand or die casting for:
- Big, simple parts
- Making lots of parts
- Lower cost per part
- When the design might change

Note: Investment casting is great for engine parts, turbine blades, and medical tools. Sand casting is used for big machine parts and pipes.

Both ways can affect the environment. Investment casting uses more energy. But companies try to waste less and recycle more. Regular casting can use more chemicals. Both ways are working to be better for the planet.

Pros and Cons

Casting Advantages

Casting is good for making big parts and simple shapes.
Many metals can be used, like aluminum, steel, and iron.
Some casting methods let factories use molds again. This saves time and money.
Casting can make lots of parts fast, so it is good for mass production.
It is easy to change designs, which helps when updates are needed.

Note: Casting is still a top pick for companies that want strong, simple parts for less money.

Casting Disadvantages

Cast parts often feel rough because of the mold’s texture.
These parts are not as exact and cannot hold tight sizes.
Problems like shrinking, gas bubbles, or sand can happen.
Workers deal with high heat and dust, which is tough.
Castings are not as strong as forged parts of the same size.

Common Issues in Casting:

It is hard to control every step.
Cast parts can have more problems.
The size is not always the same.
Castings do not hold as much weight as forgings.
The work area can be rough.

Investment Casting Advantages

Benefit	Description
Design Flexibility	Makes tricky shapes and detailed parts.
Quality Consistency	Gives accurate castings with fewer problems than sand casting.
Material Variety	Works with many metals, like stainless steel and aluminum alloys.
Cost-Effectiveness	Good for both small and big production runs.

Investment casting makes smooth parts and holds tight sizes. Wax patterns and ceramic shells help make fine details. Factories can use many metals to meet different needs. Fewer parts get rejected because of careful checks.

Tip: Investment casting is great for companies that need exact, high-quality parts.

Investment Casting Disadvantages

Limitation Type	Description
High Upfront Costs	Making wax patterns and ceramic molds costs more at first.
Time-Intensive Process	Making and drying ceramic molds takes more time.
Size Limitations	Best for small to medium parts; big parts are harder.
Labor-Intensive	Skilled workers must do the hard steps, which raises costs.
Not Ideal for Low Volumes	High costs make it less useful for very small batches.

Investment casting takes longer and costs more at the start. It works best for small or medium parts. Factories need skilled workers, so costs go up. For very small orders, other casting ways may cost less.

Choosing the Right Method

Factors

Picking the best casting method depends on many things. Every project needs something different. These points help you decide:

Material Selection: Some metals work better with certain methods. Investment casting works well with stainless steel and copper alloys. Die casting is good for non-ferrous metals like aluminum.
Production Volume: Sand casting and plaster casting are good for small batches. Die casting and permanent mold casting are best for making lots of parts. Investment casting is great for medium or big batches when you need precision.
Precision and Tolerance: Investment casting makes smooth parts with tight fits. Sand casting is less exact and leaves rough surfaces.
Part Complexity: Investment casting can make tricky shapes and tiny details. Sand or die casting is fine for simple shapes.
Budget: Sand and plaster casting cost less for small jobs. Die casting and investment casting cost more at first but can save money for big batches.
Cycle Time: Die casting makes parts fast. Investment casting takes longer because of extra steps.
Machining Needs: Investment casting needs less extra work. Sand casting often needs more finishing.

Tip: Always pick the casting method that fits your project’s size, shape, material, and budget.

Here is a table that shows how different casting methods compare for budget and how many parts you need:

Casting Method	Budget Consideration	Volume Suitability
Sand Casting	Good for small budgets	Best for small batches
Plaster Casting	Good for small jobs	Best for small batches
Die Casting	Costs more at first, good for lots of parts	Best for big batches
Investment Casting	Costs medium to high, good for exact parts	Best for medium or big batches
Permanent Mold Casting	Costs more, good for lots of parts	Best for big batches

Manufacturers know casting and investment casting are not the same. The table below shows the main differences:

Aspect	Investment Casting	Traditional Casting
Precision	High, detailed parts	Lower, simpler shapes
Surface Finish	Smooth, minimal machining	Rougher, more finishing needed
Volume	Best for small to medium runs	Suited for large batches
Cost	Higher setup, lower per-part cost	Lower setup, higher per-part cost

These things help people pick the right method. If a part is tricky and needs to be exact, investment casting is best. If a part is big and simple, traditional casting works better. Companies like KEMING check parts carefully and follow world rules. They can also make special parts for customers.

Good partners help make sure every part is made right for tough jobs.

FAQ

What is the main difference between casting and investment casting?

Casting uses molds that can be used again for easy shapes. Investment casting uses ceramic molds that are thrown away after one use. Investment casting makes parts with more details and smoother surfaces.

Which metals can investment casting use?

Investment casting works with lots of metals. Some common ones are stainless steel, aluminum, carbon steel, and copper alloys. KEMING has many materials for different jobs.

Why do companies choose investment casting?

Companies use investment casting when they need parts with exact shapes. This way makes strong, smooth, and detailed parts for planes, medical tools, and cars.

Is investment casting more expensive than sand casting?

Investment casting costs more at first because of the wax and ceramic molds. It can save money later since less extra work is needed. Sand casting is cheaper for big, simple parts.