Just because a potential buyer mispronounces the names of different casting processes does not imply that they are all created equal in their performance. As a result, determining which type is most appropriate for your project can be challenging. Die casting and sand casting are two of the most common types of casting processes used today. Here is a breakdown of each term, how the processes differ, and why you should choose either one over the other for your next project. Term 1: What is it?What Is Die Casting and How Does It Work?Die casting is a process in which liquid metal, also known as "molten metal," is forced into a die under high pressure. When we say "die," we are referring to the steel mold that will be used to shape the actual product that will be manufactured. Following the pouring and injection of the molten metal into the mold, the metal solidifies and is removed from the mold with a spatula. When the metal has cooled, the gating material is removed, and a finished product is produced! The steel mold can then be closed and prepared for the next "shot," allowing it to be reused almost immediately after being closed. When producing a die cast part, the cycle time can range from 30 seconds to one minute, making the process extremely quick. The image on the left shows the ejector half of a die cast mold, while the image on the right shows the shot taken from the mold.What Is the Process of Sand Casting?In the sand casting process, molten metal is poured directly into a sand mold from a ladle, with no need for high pressure. In order to create a mold, a pattern made of wood or plastic (typically referred to as a matchplate) is placed inside an enclosure and allowed to dry for several days. After that, sand is used to fill in the gaps around the matchplate and inside the enclosure. After the sand has been added and compacted tightly, the matchplate is removed and the remaining cavity is filled with molten metal until the matchplate is removed. As soon as the metal solidifies, the mold is opened and the sand is shaken off the hot casting, which results in the production of a finished product. By now, the gating material has been removed and the casting has been completely finished.It will then be necessary to prepare the mold for the next "shot," which will require some downtime while sand is placed around the matchplate and inside the enclosure, as in a sand casting. In order to minimize the amount of downtime that occurs (up to 5 minutes per casting), sand casting is best suited for parts that are produced in smaller quantities. A disadvantage of this process is that the materials used in it typically produce less detail in the final products, requiring more secondary operations than traditional die casting. The molds for sand casting can be seen in the image above.What is the difference between die casting and sand casting?The applications of die casting and sand casting differ from one another, aside from the most significant difference between the two processes – the materials used to form the molds – and are discussed below. Castings for medical device manufacturers, for example, will need to be precise and have complex shapes in order to be effective. Because of their requirements, die casting is most likely the most appropriate method for their project.The processes for creating a die-casted product and a sand-cast product are fundamentally different, but both have legitimate uses in commercial manufacturing. Die casting will save money in the long run for companies that have a long enough lead time and are willing to bear the higher cost of having their molds made out of steel in the short term. Reusing the dies not only ensures accuracy, but it also results in lower production costs over the course of time. For this reason, all of the items that require casting can be set up and produced in a single session, and then the process can be repeated as needed. Die casting can also produce features that are not possible with sand casting, resulting in a reduction in secondary costs when compared to sand casting.