Choosing the best casting method in 2025 depends on what your project needs. If you want very accurate shapes and small details, Lost Wax Casting is a good choice. Sand casting is better for bigger or easier parts. New data shows sand casting is used the most, with 41.20% of the market. Lost Wax Casting has 16.60% of the market and is getting more popular.
| Casting Method | Revenue Share (2024) | Market Size (2025) | CAGR (2025-2030) | Key Characteristics and Usage |
|---|---|---|---|---|
| Sand Casting | 41.20% | N/A | N/A | Most used; low cost; works for big and hard shapes; used for many metals |
| Lost Wax Casting | 16.60% | USD 17.53 billion | 5.31% | Very exact casting; smooth finish; used in planes, cars, and medicine; more people want it for hard parts |
The casting method you pick changes the price, quality, and how fast you finish. New tools like 3D printing help make molds faster and make better parts.
Table of Contents
Key Takeaways
- Lost wax casting gives very accurate and smooth parts. It works best for small, detailed, and hard shapes. Sand casting is good for big, simple, and heavy parts. It saves money on large projects. Use lost wax casting for exact shapes and hard designs. Use sand casting for bigger and easier shapes. New tools like 3D printing and machines help both ways. They make things faster and better. Think about your part’s size, shape, cost, and how many you need. This helps you pick the best casting method for your job.
Which Is Best?
Precision and Detail
If you need parts with high accuracy and small details, investment casting is the best choice. This method is also called lost wax casting. It uses a wax shape covered in ceramic to make a mold. This process copies your design exactly, so you get very accurate and detailed parts. The parts can be made with tight measurements, from about ±0.1 mm to ±0.3 mm for each inch. This is great for parts that must be measured closely and have smooth surfaces.
Sand casting uses sand molds, which are rougher. It gives you okay accuracy, with measurements from about ±0.3 mm to ±3 mm. Sometimes, you need to do more work to make the part smoother. If your project needs very close measurements or tricky details, investment casting works better.
| Aspect | Sand Casting | Investment Casting (Lost Wax) |
|---|---|---|
| Dimensional Accuracy | Moderate | High |
| Surface Finish | Rough | Smooth |
| Part Complexity | Moderate | High |
| Part Size | Large parts | Small to medium parts |
AFI Industrial Co., Ltd. is good at making lost wax castings with high accuracy. Their process gives you parts with fine details, close measurements, and smooth surfaces. This makes them a trusted company for jobs where quality and detail are very important.
Size and Simplicity
Think about the size and shape of your part before you pick a casting method. Sand casting is best for big and simple shapes. The sand molds can hold large and heavy parts, so people use this method for engine blocks, building machines, and big test parts. You can use sand casting for small or big orders, and it helps save money.
Investment casting is better for small or medium parts, especially if they are tricky or have thin walls. This method can make parts up to 1000 × 800 × 500 mm and from 0.01 kg to 100 kg. If your part has tiny details or hard-to-reach spaces, lost wax casting can make those without extra work.
Tip: Pick sand casting for big, simple parts. Pick investment casting for small, detailed, or tricky parts.
Application Scenarios
Different jobs need different casting methods. Investment casting is used most in planes, cars, and medical tools. These jobs need very exact parts, like turbine blades, engine pieces, and surgery tools. This method can make hard shapes and keeps quality high, which is important for safety.
Sand casting is still used a lot in building, energy, and transport. It is good for custom shapes, big parts, and test pieces. Sand casting is cheap for small jobs and lets you change designs fast, especially if you use 3D printing to make the patterns.
| Industry/Application | Preferred Casting Method | Typical Parts Produced |
|---|---|---|
| Aerospace | Investment Casting (Lost Wax) | Turbine blades, structural parts |
| Automotive | Investment Casting, Sand Casting | Engine blocks, transmission cases, brackets |
| Medical Devices | Investment Casting | Implants, surgical instruments |
| Construction | Sand Casting | Hinges, locks, connectors |
| Energy/Transportation | Sand Casting | Large housings, lightweight parts |
AFI Industrial Co., Ltd. makes high-precision lost wax castings for tough jobs. Their skill helps you get strong, accurate, and long-lasting parts made just for your needs.
Lost Wax Casting Overview
Process Steps
Investment casting helps make parts with great detail and smooth surfaces. This method is also called the lost wax method. It uses many careful steps to make metal parts that look just like the design. Here is how it works:
- First, you make a model from clay, wood, or plaster. This model shows the shape and details of your part.
- Next, you make a mold from the model. The mold copies every detail.
- Then, you use the mold to make a wax copy. You can add small details to the wax.
- Sprues and gates are put on the wax copy. These help the wax leave and guide the metal later.
- The wax model gets covered with a ceramic shell. This shell is strong and can handle heat.
- The mold is heated so the wax melts and runs out. Now there is a space shaped like your part.
- Hot metal is poured into the empty space. The sprue system helps fill every spot.
- When the metal cools, the mold is broken to get the part out.
- Sprues and gates are cut off, and the part is cleaned up.
- Patination can be added to protect and make the part look better.
Each step helps make sure the part is strong, smooth, and the right size. AFI Industrial Co., Ltd. uses new tools and skilled workers to make sure every part is good.
Typical Uses
Investment casting is used for many things, especially when parts need to be tricky or very exact. This process works with many metals and alloys. That makes it great for hard jobs.
| Product Types | Typical Materials | Key Features and Requirements |
|---|---|---|
| Intricate metal sculptures | Bronze | Makes shapes with lots of detail |
| Jewelry | Gold, silver, platinum | Needs to be pure, shiny, and last a long time |
| Dental restorations | Dental gold alloys, silver, copper alloys | Must fit just right and be very exact |
| Precision industrial parts | Stainless steel, carbon steel, alloy steel, copper alloys, aluminum, titanium | Can have thin walls, tiny holes, and mix many parts into one piece |
AFI Industrial Co., Ltd. gives you many choices for materials and checks quality at every step. You can count on their investment casting for planes, cars, medicine, and art. Their skill makes sure your parts are strong, detailed, and look great.
Sand Casting Overview
Process Steps
Sand casting is a good way to make metal parts. It does not cost a lot and can be used for many shapes. First, sand and clay are mixed to make a strong mold. A pattern is made that looks like the part you want. Workers press sand around the pattern to make a space for the metal. The pattern is taken out, leaving a hole in the sand. Hot metal is poured into this hole. When the metal cools down, the sand mold is broken to get the part out.
Today, people use computers and 3D sand printing to help with sand casting. These new tools help make better parts faster. Each sand mold can only be used one time. You need a new mold for every part you make. This is why sand casting works best for small or medium amounts of parts. After casting, you can grind or machine the part to make it smoother.
Note: Sand casting is fast and does not need expensive tools. You can make test parts or small groups of parts without spending a lot at the start.
Here is a table that shows the main steps and how they change speed and cost:
| Process Step | Description | Influence on Speed and Cost |
|---|---|---|
| Sand Preparation | Mix sand and clay to make strong molds. | Changes how good and cheap the mold is. |
| Pattern Making | Make molds from drawings of the part. | Easy patterns save money and make parts faster. |
| Molding | Pack sand around patterns and put mold pieces together. | More work means more time and money. |
| Melting | Heat metal in a furnace until it melts. | Changes how long and how much energy is used. |
| Pouring | Pour melted metal into the mold. | Affects how good and fast the part is made. |
| Sand Removal | Break the mold and clean the new part. | Takes more time and work to finish. |
| Grinding | Take off rough spots and make the part smoother. | Makes the job take longer and cost more. |
Typical Uses
Sand casting is picked for big or easy shapes. Many jobs use sand casting because it works for heavy and large parts. You see sand casting in cars, big machines, power plants, and building work. It is used for engine blocks, machine bases, pump covers, and truck frames.
Here is a table that shows where sand casting is used most:
| Industry/Market | Common Sand Casting Applications |
|---|---|
| Automotive | Engine blocks, cylinder heads, pistons, valves |
| Heavy Equipment | Machine bases, frames, bushings, crankshafts |
| Energy | Pump housings, valve bodies |
| Transportation | Truck chassis, axles, engine parts |
| Industrial Manufacturing | Pumps, motors, compressors, machine parts |
Sand casting lets you make just a few or many parts. You do not have to spend a lot to start making parts. You can use many kinds of metal, so sand casting is a good choice for big and simple jobs.
Comparison
Accuracy
You want your parts to fit just right. Investment casting gives very good accuracy. It can copy tiny details. Lost wax casting can be as close as ±0.1 mm. Sand casting is not as exact. It often needs extra work to be more precise.
| Casting Method | Dimensional Accuracy |
|---|---|
| Sand Casting | Moderate; often requires secondary operations to achieve precision |
| Investment Casting (Lost Wax) | High; provides excellent dimensional accuracy and intricate detail |
Surface Finish
How smooth your part is matters for looks and use. Investment casting makes smooth parts, usually between 1 and 25 microns Ra. Sand casting makes rougher parts, from 25 to 200 microns Ra. You may need to polish sand cast parts more.
| Casting Process | Typical Surface Roughness (Ra) Range (microns) |
|---|---|
| Investment (Lost Wax) | 1 to 25 microns |
| Sand Casting | 25 to 200 microns |
Complexity
If your part is tricky, investment casting is best. You can make thin walls and hollow spots. Sand casting is better for simple shapes. The pattern must come out of the sand, so you cannot make every shape.
Tip: Pick investment casting for tricky parts with small details.
Materials
Both ways let you use many metals. Investment casting works with stainless steel, brass, aluminum, carbon steel, and special alloys. Sand casting can use iron, steel, bronze, aluminum, and magnesium. Both are flexible, but investment casting gives smoother parts and more metal choices.
Cost
Cost is important for every job. Investment casting costs more for each part, especially for small orders. This is because the process takes more steps. Sand casting is cheaper for big, simple parts. For the same part, investment casting can cost 1.2 to 1.7 times more than sand casting.
Speed
You want your parts fast. Sand casting is faster for big orders and easy shapes. Investment casting takes longer because of extra steps like making wax and ceramic molds. For small batches that need to be exact, investment casting is worth waiting for.
Environmental Impact
Investment casting makes less waste and fewer emissions. It uses materials that can be recycled. The parts are almost the right shape, so there is less scrap. Sand casting tries to lower carbon by making better molds and using new tools. Both ways can save energy and recycle, but investment casting is often better for the planet.
Investment Casting Advantages
Investment casting excels in producing parts with exceptional precision and surface finish, making it ideal for applications with stringent requirements.
Superior Dimensional Accuracy and Detail
- Investment casting can produce parts with extremely tight tolerances, complex geometries, and intricate details, including thin walls and fine features. This is due to the highly accurate wax patterns and the robust ceramic shell molds.
Excellent Surface Finish
- The smooth interior of the ceramic mold results in a very fine surface finish on the final casting. This often eliminates or significantly reduces the need for secondary machining or finishing operations, saving both time and cost.
High Design Freedom
- This process allows engineers extensive design flexibility, enabling the creation of intricate designs, undercuts, and internal features that are challenging or impossible with sand casting.
Wide Material Versatility
- Investment casting is suitable for a broad range of metals, including ferrous alloys (like stainless steel and heat-resistant alloys) and non-ferrous alloys (such as aluminum and copper alloys).
Reduced Post-Processing
- Because of the high precision and excellent surface quality of investment castings, less subsequent machining and finishing are typically required, leading to lower overall production costs.
Sand Casting Advantages
Sand casting is a long-standing and widely used method, favored for its cost-effectiveness and versatility.
Cost-Effective
Sand molds are relatively inexpensive to produce, making sand casting a more budget-friendly option, especially for low-volume production runs or prototypes.
Suitable for Large and Heavy Parts
Sand casting is uniquely advantageous for manufacturing large and heavy components, capable of producing parts weighing several tons, which are beyond the practical limits of investment casting.
Faster Production Cycle for Molds
The creation of sand molds is generally quicker and simpler, potentially leading to faster turnaround times for certain projects.
Broad Material Compatibility
Sand casting can accommodate almost all types of metals and alloys, including various ferrous and non-ferrous materials.
Flexibility and Adaptability
Sand molds can be easily adjusted and modified for different shapes and sizes, offering high flexibility in production.
Technology in 2025
Digital Advances
Digital tools are changing how cast parts are made. 3D printing, like MultiJet Printing with VisiJet RealWax, makes wax patterns fast and detailed. 3D Sprint software helps you get files ready and plan the build. This digital process means you do not need extra tools, so you save time and money. Many foundries say they can make test parts faster, get smoother surfaces, and do less finishing work. You have more freedom to design and can make exact parts quickly.
| Aspect | Benefit |
|---|---|
| 3D Printing (MJP) | Fast pattern turnaround, high detail, tight tolerance |
| 3D Sprint Software | Easy file prep, build optimization |
| Digital Workflow | No intermediate tooling, lower costs |
| User Experience | Higher productivity, more flexible production |
Automation
Automation is now important for both lost wax and sand casting. Machines use CAD data to make wax patterns that are very accurate. Robots dip and coat wax patterns, so ceramic shells are always the same. Automated pouring systems control metal flow and heat, which helps stop mistakes. Advanced checks use CMMs, NDT, and AI to look for problems. These steps help make less waste, keep workers safe, and make sure parts meet strict rules.
- Robotic milling makes sand molds without needing a pattern, so you save money and space.
- AI and IoT watch the casting process, find problems early, and help fix them fast.
Automation helps you do hard jobs, need less hand work, and get better parts every time.
New Materials
You can now use new alloys that are stronger and resist rust and heat. These materials are good for planes, cars, and medical tools. Better ceramic shells make molds stronger and lower the number of mistakes in lost wax casting. 3D printing can shape these new materials into tricky molds and patterns, so it is easier to meet tough job needs.
- High-performance alloys work well in hard places
- Better ceramic shells make casting quality higher
- 3D printing helps make tricky shapes
Sustainability
You help the planet by using recycled metals and furnaces that use less energy. Many foundries use closed water systems and lean ways to cut waste. More green materials and smart systems now track energy and pollution. Life Cycle Assessment helps you see and improve your impact on the earth.
- Use recycled iron and steel to save resources.
- Pick fuels that make less pollution and make processes better.
- Reuse water and make less waste with closed systems.
- Teach your team to care about the planet at every step.
By using these steps, you follow world rules and show you care about a cleaner future.
Decision Guide
Part Size
When you choose a casting method, start by looking at the size of your part.
- Lost wax casting works best for small to medium parts that need high detail, like turbine blades or medical implants.
- Sand casting is better for large, heavy parts where fine detail is less important, such as engine blocks or machine frames.
- If your part is small and needs tight tolerances, lost wax casting gives you the best results.
- For bigger parts with simple shapes, sand casting is the practical choice.
Tip: Match your part size to the strengths of each process for the best outcome.
Complexity
The shape and detail of your part matter. Use this table to help you decide:
| Casting Method | Best For | Tolerance Level |
|---|---|---|
| Sand Casting | Simple or moderately complex shapes | Looser (ISO 8062 CT10-12) |
| Lost Wax Casting | Highly complex, detailed parts | Tight (±0.1 mm possible) |
If your design has thin walls, small holes, or tricky features, lost wax casting handles complex shapes with ease. Sand casting can make some complex parts, but it cannot match the fine detail or tight tolerances of lost wax casting.
Budget
Budget often guides your decision. Lost wax casting needs a higher upfront investment for steel dies, which can cost from $15,000 to $60,000. This makes it best for projects where precision matters and you plan to make many parts. Sand casting has lower tooling costs, so it fits smaller runs or prototypes. If you need to control costs and do not require high precision, sand casting is the more affordable option.
Volume
Think about how many parts you need. Lost wax casting is most cost-effective for medium to high production volumes. The process gives you excellent detail and finish, which pays off when you make many parts. Sand casting suits low to medium volumes, especially when you want to change designs quickly or need a fast turnaround.
Finish
Surface finish affects both looks and function. Lost wax casting produces smooth, high-quality surfaces with little or no need for extra machining. Sand casting leaves a rougher finish, so you may need to machine or polish the part after casting. If you want a part that looks good and needs little finishing, choose lost wax casting.
For expert advice and a solution tailored to your needs, consult AFI Industrial Co., Ltd. Their team can help you select the right casting method for your project.
Case Studies
Lost Wax Casting Examples
Lost wax casting is used in many modern industries. In aerospace, it helps make turbine blades for airplane engines. These parts must be strong and exact. Lost wax casting can make tricky shapes with close measurements. One big aerospace company made stronger parts and saved money by using investment casting. In cars, lost wax casting is used for exact parts like brackets and housings. Aluminum alloys keep these car parts light and tough. Medical device companies use lost wax casting for implants and surgery tools. Stainless steel and titanium help these parts fight rust and stay safe.
AFI Industrial Co., Ltd. has made lost wax castings for hard projects. Their team made stainless steel surgical implants with tiny inside spaces for a medical company. In cars, AFI made light aluminum brackets that passed European quality checks. Their skill in picking materials and checking quality gives you strong, good parts.
| Industry | Application Examples | Materials Used |
|---|---|---|
| Aerospace | Turbine blades, engine components | Stainless steel, titanium |
| Automotive | Precision brackets, housings | Aluminum alloys |
| Medical Device | Surgical implants, device parts | Stainless steel, titanium |
Sand Casting Examples
Sand casting is best for big or heavy parts. Truck and machine companies use sand casting for engine blocks, machine bases, and gearbox housings. This way can make parts from 1 pound to 1,000,000 pounds. You can make tricky shapes and still save money.
- A truck company used sand casting to make a huge engine block. The part was very heavy and had to handle a lot of force.
- An aerospace company made a bracket with exact size and strong features using sand casting.
- A gearbox company made a part with detailed gear teeth inside, showing sand casting can make tough, tricky parts.
You can count on sand casting for big jobs that need to be strong and last long. This method is good for industries where size and strength are very important.
Choosing between lost wax casting and sand casting depends on your project’s needs. Lost wax casting gives you high precision and smooth finishes for complex parts. Sand casting works best for large, simple shapes at a lower cost.
- Match your part size, detail, and budget to the right method.
- For expert guidance, reach out to AFI Industrial Co., Ltd.
Stay informed about new casting technologies to keep your projects ahead in 2025.
FAQ
Lost wax casting gives you high precision and smooth surfaces. Sand casting works best for large, simple parts. You should choose lost wax casting for detailed designs and sand casting for bigger, less complex shapes.
You can use both methods for many metals. Lost wax casting supports stainless steel, aluminum, titanium, and precious metals. Sand casting works well with iron, steel, bronze, and aluminum. Always check your project’s metal needs before choosing.
Tip:
Check your part’s size, detail, and budget. Use lost wax casting for small, complex, or high-precision parts. Pick sand casting for large, simple, or cost-sensitive projects.
Yes, lost wax casting usually costs more per part. You pay for higher accuracy and better surface finish. Sand casting costs less, especially for large or simple parts.
