Simulated die casting is a specialized casting technique for aluminum and zinc castings that uses a plaster medium with a split tool system. This process creates castings comparable to die casting methods without the high tooling cost.
Why Simulate Die Casting?
Die casting produces high-quality results, but it’s often more expensive because the molds must be strong enough to reuse. In high-volume applications, large production runs often offset the cost, but investing in this superior casting process is difficult for low-volume runs. At FastCastings, we use plaster molds to simulate the quality of die casting but with greater detail and better surface finishes than traditional sand casting. Plaster casting features expendable molds, which are ideal for unique, complex castings.
With plaster, we can achieve thin walls and meticulous detail—these advantages combine to create a high-quality finish. We can execute .070”-.125” nominal wall thickness, which is much thinner than what traditional sand casting can do. Our simulated die casting method can achieve +/- .015”-.025” tolerance control as cast.
Plaster Mold Casting Process
Though plaster of Paris is one component, the casting material also includes additives to improve its strength and effectiveness.
Before pouring the plaster mixture into the metal pattern, we use a spray compound to prevent sticking. Once the plaster has set, we remove the mold and heat it to dry it out. Now the mold is ready for casting. Once the poured metal has hardened, we break the plaster to remove the finished part.
Because the removal process involves breaking the plaster, we cannot reuse the molds. However, the superior detail and quality finish we can achieve with this process makes it an ideal solution for short-run manufacturing needs.
Request a Quote
If you want to learn more about our simulated die casting techniques, contact us now for more information or to request a quote. We can help you determine if our plaster mold casting process is the right choice for your application.