The Ultimate Precision Casting Guide: Techniques & Applications

What Is Precision Casting?

Casting is a process where foundries create products for certain purposes, from gears for automobiles to operating tables for surgeons. Casting can use a number of different materials depending on the processes used; for example, foundries can use a different number of materials that are based on the end use of the part. 

Precision casting is one type of commonly used casting process that differs from the rest. Precision casting tends to be a more costly option than traditional sand casting, but precision casting comes with a multitude of benefits. Precision casting is a unique form of casting in that it creates quality, complex castings and uses a different process than sand casting. Because the precision casting process results in the most quality products, it’s a good option for highly specialized industries or businesses’ unique casting needs. 

What Is The Precision Casting Process?

The precision casting process differs from the typical sand casting process, requiring more time and effort but producing a far more quality product. Most foundries use sand to create a mold in which the metal is poured. Permanent mold uses various speciality steel alloys to make the mold. The same permanent mold can be used numerous times, whereas the sand mold is only used once. 

What Industries Use Precision Casting?

Precision casting is used in a number of different industries for a variety of purposes. Precision casting is useful for those who need highly specialized castings, since precision casting allows for significant freedom of design. Each industry has individual applications, and therefore may have different requirements and needs for precision casting. 

The following industries may use precision casting:

• Agriculture – Those who work in agriculture tend to use a number of mechanical tools and machines to complete tasks, from tractors to manure spreaders. Precision casting can create parts for agricultural machines and agricultural tools for nearly any purpose, including custom designs.
• Medical/health care – Medical parts require some of the most precise pieces of any industry, making precision casting a great choice for healthcare products. Using precision casting in the medical industry allows for clean, durable, perfectly-cut tools.
• Energy – The energy industry, particularly the renewable energy industry, requires precision casting to create products that fuel our homes, businesses and favorite recreational locations with sustainable energy.
• Food – Many of those in the food industry choose to use precision casting rather than sand casting since precision casting creates smoother products. Smoother products are less inclined to bacterial growth and contamination. 

Other industries that may use precision casting include electronics, textiles, chemical manufacturing, construction and even sports. 

What Types Of Products Come From Precision Casting?

Each industry has different needs that may be fulfilled by precision casting. Because precision casting is so versatile, casters can make custom products for businesses. While one industry may need small, intricate products with complex gears, another may require simpler, food-safe surfaces. Precision casting can fulfill all of these needs thanks to the foundries ability to create highly-customized products.

While precision casting has few limitations and nearly any custom cast can be created, these are some of the most commonly requested items in a few of the most popular industries:

• Electrical – Due to permanent high conductivity copper it can be used in a variety of electrical applications. 
• Agriculture – Gears, valves, covers, housings
• Automotive – Engines, car parts, various hardware items 
• Mining – Gear housings
• Energy – Clamps, valves, gas regulators, meter housings

Why Is Precision Casting A Good Option?

Precision casting is a uniquely strong casting choice for many different industries for a number of reasons. Unlike traditional sand casting, precision casting results in a highly smooth finish. This can eliminate additional machining. 

Precision casting also allows for more detail and freedom of design. While traditional casting is limited in how much detail can be provided in each design, precision casting can create nearly any product a company needs, according to their exact specifications. Because this process requires so much exactness, mistakes, defects and other issues are less common in precision casting than in traditional sand casting.