Premier Aluminum Casting Methods

Premier produces permanent mold castings using four methods. This versatility can best serve each application and various casting designs.

Low Pressure

Air pressure is used to force molten metal upward into a closed die cavity. This is an excellent process for circular designs as well as pressure tight vessels. These castings approach the surface finish of die castings and create a denser casting, without the higher tooling cost.

Tilt Pour

Molten metal is transferred from a holding cup into the mold in a precise microprocessor controlled sequence. This method offers high quality consistent parts to the widest variety of sizes and shapes.

Static Pour

Molten metal is ladle-poured from the top directly into a die cavity. This method is normally used for center-feed castings and accommodates a wide range of small to large castings.

Semi-Permanent Mold

Preformed sand cores are used with the methods described above. This allows casting of internal shapes, features or undercuts when “hard tooling” is not the best option.

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Aluminum Castings: Process Comparisons

Process Typical Size Range Tolerances Surface Finish Min. Draft Required Min. Section Thickness Typical Tooling Costs Part Cost Nominal Lead Time
V-PROCESS Up to 150 lbs +.010″ for the first 1″, then add +.002″ per inch.
Add a maximum .020″ across parting line.
125 – 150 RMS None .125″ $3000-$15,000 Very High Samples: 2 to 6 weeks.
Production: 2 to 6 weeks after approval.
Sand Castings Ounces to tons +1/32″ to 6″, then add + .003″ per inch.
Add + .020 to .090″ across parting line.
250-500 RMS 1 to 5 degrees .25″ $2000-$15,000 Low Samples: 2 to 6 weeks.
Production: 2 to 6 weeks after approval.
Investment (lost Wax) Ounces to 20 lbs + .003″ to 1/4″
+ .004″ to 1/2″
+ .005″ to 3″, then add + .003″ per inch
63-125 RMS None .060″ $3000-$20,000 High Samples: 8 to 10 weeks.
Production: 5 to 12 weeks after approval.
Permanent Mold Ounces to 100 lbs + .015″ to 1″, then add + .002″ per inch.
Add + .010″ to .030″ across parting line.
150-300 RMS 2 to 5 degrees .150″ $10,000-$50,000 Low Samples: 8 to 20 weeks.
Production: 10 to 12 weeks after approval.
Plaster Mold Ounces to 50 lbs + .005″ to 2″, then add + .002″ per inch. Add + .010″ across parting line. 63-125 RMS 1/2 to 2 degrees .070″ $3000-$15,000 High Samples: 2 to 10 weeks.
Production: 4 to 8 weeks after approval.
Die Casting Ounces to 15 lbs + .002″ per inch.
Add + .015″ across parting line.
32-63 RMS 1 to 3 degrees .030″ to .060″ $125,000-$250,000 Lower Samples: 12 to 22 weeks.
Production: 8 to 14 weeks after approval.