The Cost of Investment Casting

Investment casting, also known as Lost-waxing or precision casting, is an industrial process that shapes a disposable ceramic mold with a wax pattern. To cast an item in the exact shape, a wax pattern is created. After the ceramic type of material has hardened, it is heated and rotated upside-down until the wax gets to melts and also drains out. The toughened ceramic shell serves as an investment mold that can get replaced. The molten metal is then added to the mold and allowed to cool. After that, the metal casting is broken free from the used mold.

In modern casting technology, investment casting is the most widely used technology. It can help customers save a lot of raw materials and lower their input costs.

How Much Does Investment Casting Cost?

There are several costs associated with investment casting. While each project’s actual Investment Casting Cost will vary due to the uniqueness of each instance, there are crucial elements that will affect the ultimate pricing. Knowing what they are will assist you in preparing your budget by allowing you to factor in your castings. Take a look at the factors that can affect the total cost of the investment casting process below.

· Type of Metal

Its intended use determines the metal used in the investment casting. The requirement will always come from the engineer who designed the casting. Other factors that influence material selection include properties, availability, and price. The cost of the same metal or alloy will fluctuate over time due to availability and even the global economy; interest rates and transportation costs can also affect the price of materials.

Brexit, for example, could have an impact because the UK is not again going to benefit from any preferential tariffs with any country if it leaves the European Union. Some metals and alloys will remain more expensive than others; titanium, for example, is significantly more expensive than aluminum.

· Rapid Prototyping

Rapid prototyping is an option if your project requires a prototype to test the practicality and functionality of your design. This should later give you a good understanding of how the part will function in actual situations.

There are lots of advantages to using this service. It has a short production time and can assist you in validating or comparing several casting options before full-scale roll-out. It also allows you to make design changes without making costly changes to the final part, and it is manufactured from your CAD data.

Many rapid prototyping methods are available; however, creating a high-quality, high-integrity casting with dimensional accuracy and a quick turnaround costs more, so keep that in mind before making your choice.

While rapid prototyping requires an initial investment, it may turn out to be the most cost-effective solution in the long run.

· Design Complexity

The Cost of Investment Casting can also be influenced by how easy it is to shell it. Reduced airflow during drying is expected for projects with more complex geometries, but it can extend the time it takes to fully dry the part, which can cause the binder in the ceramic slurry to set, slowing production.

The number of shell layers is also a consideration.  The more complicated the structure you need in your project, the more layers you’ll need, which will cost more.

· Production Technique or Technology

The method of production used, as well as the technology used, can have an impact on the final cost. Of course, the tighter the tolerances and the more precise the dimensions, the more expensive a part can be, so keep that in mind as well.

· Production Technique or Technology

The method of production, as well as the technology used, can influence the final cost. For different requirements, different methods will be best suited.

Investment Casting Cost Estimation

These days, competition is increasing at an exponential rate. The investment casting industry must meet ever-higher customer expectations regarding quality standards and lower pricing to survive and compete globally.

Investment casting process planning entails selecting a suitable casting process and a variety of investment casting materials. It is now necessary to develop an easy-to-use casting cost estimation methodology to maintain continuous cost reduction in the casting process.

It’s also worth noting that all-inclusive Investment Casting Cost Approximation Procedure must be capable of identifying the most critical casting cost parameters. The material cost estimation and tooling process are the essential features of investment casting.

Material Cost Estimation

The cost estimation of indirect and direct materials is the two most crucial factors for Investment Casting Material Cost Estimation

· Direct Material Cost

An estimate is made based on cast metal or alloy materials in any product indirect material cost. However, when it comes to direct material costs, the metals or alloys used can be determined by the weight of the investment casting.

· In-direct Material Cost

Molding sand, dispensable cores, and feeding aids are examples of in-direct materials that vary by casting process.

Furthermore, when it comes to in-direct material costs, the price of molding sand is an essential factor to consider. The type and composition of the sand and the size of the mold determine the cost of molding sand. The cost of core ore sand is also determined by the type of sand used and the number of cores required. In addition, the cost modifiers for mold rejection and core rejection must be thoroughly understood.

The idea here is that the recycling element is highly relevant in the case of indirect material prices. First, it helps determine how much new sand is needed for each mold or core. Then, the rejection factor is used to calculate the account breakage or damages.

Here’s what I’m trying to say: In indirect material costs, the recycling factor is critical. It assists in determining the precise amount of new sand required for each mold or core. The account breakages or damages are measured using the rejection factor. Furthermore, the cost of mold sand is divided by the number of casting cavities to determine the cost of mold sand per casting.

Tooling Cost Estimation

Because the tooling is the most important aspect of casting, its cost estimation cannot get overlooked. In addition to investment casting, it includes a core box for sand casting, an outline and a metal mold for die casting. The material and manufacturing of the tooling determine the cost, and the material is chosen based on the tool life required, which is further influenced by the order quantity.

The surface area is usually compared to a cube of equal volume to calculate the area complexity factor. This is because a cube is the most basic shape and has the smallest surface area for a given volume.

Why is investment casting expensive?

Complex designs may necessitate additional processes and treatments, which can increase the part’s cost. The number of shell layers is another factor to be considered.  The more complicated the structure you need in your project, the more layers you’ll need, which will cost more.

How are Investment casting prices calculated?

The weight-based method entails keeping track of all expenses (material, energy, labor, and so on) and the total weightiness of salable casting produced over a set period.

The average rate of Investment castings quantity is calculated using this information, and it is used to calculate the cost of new castings based on their weight.

Investment Casting Product Examples

Investment casting allows manufacturers to create a wide range of products.  Below are few examples of investment casting products list

• Auto parts
• Aerospace-grade airplane engine turbine components
• Agricultural machinery parts
• Surgical instruments

Conclusion

Today, calculating the cost of investment casting has become one of the most critical variables in the growth of any metal casting. The appropriate and precise cost estimates of investment casting are critical to the successful completion of any project.

Forecasting the cost of future projects is critical to any business or organization’s survival as a project is proposed and then developed from the owner’s perspective; the cost estimate aids in determining the project scope. So, if you’re in the investment casting business, make sure you have an investment casting cost estimate in place to ensure successful project completion.