Permanent Mold Casting Services
ISO 9001:2015 Certified for High Quality, Large Scale Components
At Spectron Manufacturing, our low pressure permanent mold casting process utilizes a bottom feed bottom fill process resulting in superior metal quality, cost efficiency for larger parts, and the ability to handle complex internal geometries. This process is ideal for applications with larger part sizes, internal geometries requiring disposable sand cores, and lower quantity production runs that can benefit most from decreased upfront tooling cost.
No Waiting, No Delay
Quotes typically delivered in 3 days
Get a Permanent Mold Casting quote
Get an accurate quote for your Metal Casting project. Provide us with the specifics, and our team will review your requirements to offer a custom tailored solution.
Trusted by
What Is Low Pressure Permanent Mold Casting?
Low pressure permanent mold casting is a highly versatile casting process that produces parts with excellent metal quality and complex geometries. It’s particularly cost effective for larger parts and smaller production runs, offering a reduced tooling cost relative to die casting while retaining many of the benefits of repeatability and good surface finish.
Spectron uses a bottom pull bottom feed injection system meaning that molten metal is pulled from deep within the crucible where surface contaminants are least and the molten metal is pushed upward into the bottom of the die cavity, filling it with a bottom to top slow laminar pooling effect which reduces the chance of porosity and other defects. This process is ideal for larger, thick walled parts where dimensional accuracy and surface finish requirements exceed what sand or investment casting can offer. The low pressure injection also allows for disposable air set sand cores which makes complex internal geometries typically only associated with investment casting an achievable goal. Common applications include automotive, agricultural, and industrial industries.
Permanent Mold Casting Tooling
Our permanent mold tooling utilizes durable nodular iron molds, offering higher repeatability and enhanced surface finish relative to sand or investment casting processes. When compared to high pressure die casting the nodular iron tooling offers significant cost savings.
Tooling Lead Time:
4 weeks
Production Lead Time (Qty 1k)
3-4 weeks
Sample Lead Time:
1-2 weeks
Tooling Life Expectancy:
100k shots
Production Process
Our permanent mold casting process ensures precision and quality at every step.
Tooling
Design and manufacture of custom casting molds.
Samples
Prototype castings produced for testing and refinement.
QC
Inspection to verify sample accuracy.
FAA
First Article Approval by the client.
Production
Full-scale casting production begins.
QC
Final inspection of finished components.
Shipping
Secure packaging and delivery to the client.
Project Assessment
Start with a Free 30-Minute Project Evaluation.
Complete a quick project assessment to schedule a free consultation with Spectron’s engineering team. Gain expert guidance on casting, machining, and production planning from industry veterans as we review your design, materials, and objectives to identify the ideal manufacturing solution. Each consultation is fully tailored to your parts and project.
Materials We Use
We work with a wide range of non-ferrous materials to ensure that your parts meet the requirements for strength, durability, and surface quality.
Common Materials Include:
Aluminum Alloys:
Known for their excellent strength-to-weight ratio, corrosion resistance, and thermal conductivity, these alloys are ideal for demanding applications.
Not sure what’s right for your project?
We can help guide you down the right path.
Advantages of Permanent Mold Casting
1. Superior Metal Quality Due to Laminar Fill Process
The bottom pull bottom feed injection process pulls metal from the bottom of the crucible where less impurities are present, the molten metal is then fed at a pressure of 6-12 psi into the bottom of the mold pooling upward maintaining a singular plane of metal in contact with the oxidizing air. This metal is then pushed out the top of the mold into a gate which is later discarded resulting in denser, higher-quality castings with fewer internal defects.
2. Ability to Cast Complex Geometries with Sand Cores
Permanent mold casting can utilize disposable sand cores, allowing for the creation of intricate internal shapes and complex external geometries. This flexibility is ideal for parts requiring detailed internal passages or complex designs that are difficult to achieve with other casting methods..
3. Lower Tooling Costs Compared to High-Pressure Die Casting
The use of cast nodular iron molds offers significant cost savings over high pressure die casting. This makes permanent molding a cost effective solution for larger, thicker parts, as well as lower quantity requirements.
4. Cost-Effective for Lower Production Quantities
This process is well suited for low to medium production volumes. It provides an economical option for clients needing a similar quality to die cast parts without committing to the higher tooling costs associated with high-pressure die casting. It is also an excellent alternative to die casting in that it offers superior metal quality for thicker walls, longer runs, and larger parts.
5. Ideal for Parts Over 12″ in Size
Permanent mold casting is especially well suited for larger components due to its bottom pull bottom fill injection process and slower solidification rates. The process can accommodate large castings without requiring the very expensive tooling and extreme tonnage specialty die cast machines which are otherwise required.
6. High Dimensional Accuracy
Compared disposable mold processes like sand casting, investment casting, and plaster casting permanent mold casting has higher repeatability resulting in tighter tolerance capabilities. This often leads to a reduction of costly post-machining requirements.
Design Specifications
for Permanent Mold Casting
Our low-pressure permanent mold casting process provides excellent control over part tolerances and surface finishes, making it ideal for high-quality, complex components.
Wall Thickness
Minimum wall thickness of .18″ (4.5mm) for aluminum alloys.
Surface Finish
Typical surface finish is Ra 125 micro-inch as cast; post machining is available for higher quality finishes.
Tolerances
As cast tolerances as tight as +/- .010” (.025mm) for the first inch and +/- .003” (.075mm) for each additional inch, ensuring precise dimensions for critical components.
Draft Angles
Minimum draft of .5 degrees ensures smooth ejection from the mold without compromising part integrity.
Permanent Mold VS. High Pressure Die Casting:
Which Is Right for Your Project?
While high pressure die casting is ideal for high volume production and thinner wall sections, permanent mold casting is well suited to lower quantities and larger, more complex parts.
| Permanent Mold Casting | High Pressure Die Casting | |
|---|---|---|
| Ideal for | Lower quantities, larger, complex internal geometries | Higher volume production, thinner wall parts |
| Metal Quality | Superior quality on thick walls or long runs | Excellent quality within parameters |
| Tooling Costs | Lower upfront cost | Higher upfront cost |
| Production Speed | Slower casting cycles / higher reoccurring costs | Faster casting cycles / lower reoccurring costs |
| Minimum Wall Thickness | Thicker .180” (4.5mm) typical | Thinner wall .080″ (2mm) typical |
Our Expertise, Your Vision
Contact us, lets discuss your project.