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Die Casting vs. Sand Casting – What’s the Difference?

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Die casting and sand casting are two popular methods for manufacturing metal parts. While both methods involve casting liquid metal in a mold to create a product or part, there are significant differences between the two processes.

What is Die Casting?

Die casting is a manufacturing process that involves injecting molten metal into a complex, highly engineered multi-component steel mold, or “die,” that is set in a machine that controls the clamping, metal injection, die opening, part ejection/extraction, die cooling, and lubrication processes. Die casting can be used with various metals, including aluminum, magnesium, and zinc. Each metal has unique properties and benefits (learn about them here), suitable for countless applications.

Die casting uses sophisticated hydraulics to inject molten metal into the steel die with tremendous speed and pressure. The machines can apply hundreds of tons of locking force to hold the die shut during metal injection. The water-cooled die extracts the heat, causing the metal to solidify quickly – this process can run up to 100 cycles or more per hour. The machine then opens the die. The part is automatically ejected and (typically) placed into a trim die where the excess material is sheared away, leaving a near-net-shaped part. In some die casting processes, “in die” de-gating separates the excess material from the part resulting in a net shape part produced directly from the casting process.

Automated systems then cool and lubricate the die surface after each cycle.

What is Sand Casting?

Sand casting is a metal casting process that uses sand as the mold material to create parts. This process is best suited for low-volume production.

Molten metal is poured into the cavity through a sprue channel. The metal fills the cavity and takes on the shape of the part. Once the metal has cooled and solidified, the sand mold is broken apart to reveal the casting. Excess material is then removed from the casting by band sawing and grinding.  

Advantages of Die Casting

Here are some benefits of die casting over sand casting:

  • Precision: Die casting produces parts with tighter tolerances, thinner walls, and lower draft which results in less secondary machining compared to sand casting.
  • Surface finish: Die casting provides a smoother surface finish than sand casting.
  • Efficiency: Die casting is a faster and more efficient process resulting in lower part cost.

While sand casting has advantages for certain applications, die casting allows for faster production rates, lower labor costs, and the ability to produce more complex shapes and thinner walls – making it a popular choice for high-volume applications. If you think that die casting might be the right fit for your project, contact us today. You can also request a quote here.

CWM Recycling Statistics – February 2023

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In February 2023, CWM recycled the following:

  • 80 lbs. of paper
  • 1,742 lbs. of cardboard
  • 152 lbs. of plastic
  • 1,987 lbs. of wood
  • 950 lbs. of mixed recyclables

A total of 4,911 pounds of recyclable materials were diverted away from a landfill! Learn more about CWM’s dedication to improving environmental standards and our various certifications and accomplishments.

CWM Recycling Statistics – January 2023

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CWM’s goal is to be as transparent as possible with our customers about our environmental impact. To that end, we have started a blog series showing how we are reducing our carbon footprint.

In January 2023, CWM recycled the following:

  • 102 lbs. of paper
  •  2,233 lbs. of cardboard
  •  237 lbs. of plastic
  •  12 lbs. of Styrofoam
  •  2,898 lbs. of wooden skids

A total of 5,482 pounds were diverted from the landfill, and 8 cubic yards of mixed recyclables were sent to our partner, Groot, for recycling.

CWM's recycling Baler

Where Does It All Go?

CWM purchased a baler in 1997; back then, Loop Recycling picked up our baled cardboard. Loop Recycling created a use for this scrap cardboard by selling it to companies that made bedding material for farm animals. 

We currently ship our cardboard to Imperial Recycling. Imperial consolidates materials, and it eventually goes back to the producers, where it is converted back into new cardboard.

Learn more about CWM’s dedication to improving environmental standards and our various certifications and accomplishments!

Inside CWM Summer 2022 – Vol. 18 No. 2

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In the Summer 2022 edition of Inside CWM you can learn about:

  • CWM’s Production Manager Jim Reitenbach reflects on his 40 years of experience and how things have changed. 
  • The 7 Reasons to Keep Die Casting Projects in the USA.
  • Margo shows off her “CWM Zoo” in our #TBT Animal Corner.
  • CWM employees take time to celebrate the good things that happened to them and their families over the summer!
  •  Meet CWM’s two Fútbol clubs.
  • Get an update on CWM’s Scholarship recipients who are currently in school!
  • Meet CWM’s “new” employees!
  • Compete in CWM trivia and see how much you know about the history of CWM!

Click here to read Inside CWM Summer 2022 – Vol. 18 No. 2

The Benefits of High-Volume Production in Die Casting

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CWM building logo
Chicago White Metal’s High Pressure Die Casting process is the perfect solution for high-volume manufacturing projects – especially if you are concerned with cost, efficiency, repeatability, and producing high-quality parts. High-volume manufacturing, via the high-pressure die casting process, involves an investment in tooling, but the benefits are that parts can be converted from raw material to finished part very quickly, with minimal part-to-part variation and significant cost savings. Because manufacturers can produce parts more efficiently, high-volume production decreases the cost of production per unit. In the case of high-pressure die casting, parts can be converted from raw material to finished part in seconds.
High-volume production is also the most efficient way to turn around a large order of parts or products in a short amount of time, allowing products to get to market faster and for organizations to stay on the leading edge of innovation. In a competitive economy where companies continually introduce new items, the time and money saved with high-volume production can set an organization up for success.

Past vs. Present

In the past, a manufacturer might have only been able to produce a small number of parts per day. Machinery advancements enabled output to increase. For example, the first documented use of the die casting process was in the mid-19th century. It involved manually pouring molten metal into a die that opened and closed using a primitive machine. Today’s manufacturers, when employing state-of-the-art machinery and a skilled team, can produce thousands of units per day, if not more.

Modern high-volume die casting takes advantage of automation, including robotics, sophisticated controls, camera systems, sensors, and other technical advancements. These innovations offer many benefits, including repeatability, higher quality products, and lower (and more predictable) long-term costs of operation. However, successfully scaling to high-volume manufacturing requires foresight and planning to streamline the production process and minimize changes.

Scaling – Best Practices

Scaling up a product from the prototype or low-volume production stage (such as a machined part) to a high-volume manufacturing environment (such as high-pressure die casting) can be one of the most exciting stages of the production process. The decisions made during this transition will have significant implications for all aspects of a product, from tooling and manufacturing process control, to packaging and user documentation. That’s why it’s crucial to have an experienced team around you to help guide you through the process.

Here are some questions to ask yourself before considering scaling up to a high-volume manufacturing process such as high-pressure die casting:

  • Are you confident you’ll need enough parts to justify the tooling investment required for high-pressure die casting?
    • The typical quantity for high-pressure die casting is 5,000 pieces per year for several years (often much higher). There are exceptions, but the higher the volume, the more likely the high-pressure die casting process would be the right choice for your product.
  • Will the alloy offered by the die caster be suitable for your application?
    • Some of the more common die casting alloys include A380 aluminum, AZ91D magnesium, and Zinc #3.
    • Ferrous alloys are not an option for high-pressure die casting.
  • Is your design appropriate for high-pressure die casting?
    • Die casting is more likely to be the right choice if the design is three-dimensional and not easily stamped or extruded.
  • Is the design optimized and stable?
    • In order to maximize the payback from the tooling investment, it’s crucial to optimize the design and be sure that it is relatively stable before building tooling, as making changes to tooling after it is constructed can be expensive.

Partnering with the Right Die Caster

If you think your part is eligible for high-pressure die casting, it’s vital to seek out a reputable die caster who has enough experience to guide you through the process of selecting an appropriate alloy, optimizing the design, building robust high-quality tooling, and developing an optimized set of processing parameters. There are numerous areas where an experienced die caster can help your organization ramp up to higher-volume production.

Engineering Design Services, for example, offers tremendous value to the customer because the greatest opportunity for cost savings comes in the design phase before the tooling is built. As part of their design service, CWM uses sophisticated modeling and simulation tools such as Magmasoft and SolidWorks – a solid modeling computer-aided design and engineering application – to help design parts and tooling of the highest quality and lowest cost.
CWM building logo

When you collaborate with a die caster who utilizes this state-of-the-art technology, it ensures that your part is manufactured efficiently over the entire product lifecycle – that’s why it’s essential to have a team of experts available to work with you throughout the process.

CWM & High-Volume Production

CWM’s approach to high-volume production is the same in all we do: Excellence is expected. Our engineering and manufacturing processes are streamlined to benefit our customers’ needs. For example, if high-pressure die casting makes sense, we will provide accurate estimates of the cost of tooling and parts, including complete finishing, coatings, etc., and we will work with your team to make sure the part is a success.

Chicago White Metal specializes in high-volume production of Aluminum, Magnesium, and Zinc die cast parts. We supply numerous industries with parts that are used in everyday products across the world. Don’t hesitate to contact us if you want to learn more about our high-volume die casting services.

Inside CWM Spring 2022 – Vol. 18 No. 1

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In the Spring 2022 edition of Inside CWM you can learn about:

  • CWM Celebrates our 85th Anniversary in 2022!
  • Learn about the Benefits of High-Volume Production.
  • Meet the “new” CWM team members and our Summer Interns, and see who retired in 2022.
  • We throw things back to the CWM 75th anniversary party with some pictures.
  • Find out about CWM’s most recent Green Initiatives — including initiating a new Styrofoam recycling program.
  • Find out what happened at CWM’s 42nd Annual Golf Outing.
  • See who won the CWM Bracket Challenge and what charities they donated to.

Click here to read Inside CWM Spring 2022 – Vol. 18 No. 1

CWM’s Recycling Program – Above and Beyond

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CWM’s Recycling Program – Above and Beyond

Chicago White Metal’s environmental practices began long before cultural demands for sustainability started. Reduce, Reuse, Recycle has always been the mantra throughout our operations and supply chain. In both our plant and office operations, recycling comes first.

One of the main reasons CWM maintains such a rigorous recycling program is due in large part to employee dedication. The recycling program has expanded year-to-year thanks to Senior Management’s commitment to excellence in all aspects of the business, especially when it comes to environmentalism.

Recently, Tom Mrock, CWM’s New Product Finishing Manager, took the time to meet with all CWM employees to refresh them on what is and isn’t appropriate for recycling. Tom also educated everyone about “Plastic Free July,” which CWM looks forward to participating in this year. Small steps like that can make a big difference in protecting the environment and maintaining our reputation as an industry leader. 

CWM’s Environmental Policy & Recycling Program

Chicago White Metal is committed to protecting and preserving the environment in everything we do – from recycling scrap metal to something as small as putting the right paper or plastic into the correct recycling bin. We strive to be recognized by our customers, employees, and community as a responsible business committed to evolving our practices to meet the ever-growing demand for environmental sustainability.

As we continue developing our environmentally responsible culture, CWM consistently refines our Recycling Initiatives to focus on environmentally friendly manufacturing principles and general waste reduction. Not only do we hope to reduce our carbon footprint, but also one of our main objectives is to encourage suppliers, neighbors, and customers to adopt similar programs so they can do the same – after all, we’re all in this together.

Click here to view CWM’s full environmental policy.

How it Works

CWM’s recycled materials, such as plastic, steel, cardboard, and electronics and typically sent to a certified recycling vendor. As part of our recycling program, CWM takes extra steps that require our recycling vendors to provide a full manifest/certification and/or detailed process map that illustrates precisely how recyclables are processed.

In addition, CWM also worked with suppliers of office items like plastic coffee stirrers, lids, and plastic utensils to see if we could find a more environmentally option. These changes led CWM to eliminate Individual Plastic Beverage Containers (PCBs) and single-use plastic items and replace them with more environmentally friendly alternatives in 2019.

Learn More

To learn more about the history of CWM’s 30+-year-old recycling program, visit our Environmental Practices page. In addition, you’ll find information about CWM’s ISO 14001 and ISO 9001 certifications and additional details about CWM’s ever-evolving Recycling Program.

Environmental stewardship is something that we take very seriously at CWM. Our ability and willingness to adapt and change to continually evolving environmental standards have allowed us to remain at the top of the industry. See numerous examples of our environmental practices throughout our website, or contact us today to learn more.

CWM Invests in Robotics and Automation

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FANUC CNC Robot die casting
FANUC CNC Robot die casting

Chicago White Metal remains very proactive in the research and implementation of advanced technology into the die casting process, added value and finishing operations. CWM leadership encourages an environment where team members can examine and suggest alternatives to current techniques in order to improve and enhance quality, efficiency and measurability.  This ultimately leads to an overall efficiency for existing and future projects.  The team is always excited at the prospect of taking an original idea and watching it grow into a reality.

One idea that came to life in 2021 is the implementation of robotics and automation technology in the CNC department. There are currently 6 active robot implementations: 4 Universal Co-bots and 2 Fanuc Robot Cells.  These robots were commissioned quickly in the past 12 months, calling for the promotion of Daniel Lechuga to Automation Specialist in order to keep up with the equipment maintenance and wiring.

The Fanuc Robot Cells are dedicated to several tasks such as facilitating added value and finishing operation checks, leak testing several parts at a time, and tending to CNC machinery.  This allows team members to tend to other machines and focus on performing more critical tasks.  The Fanuc robots were the first to be integrated into the CNC department and can be seen on the shop floor with cages around them.  They are currently facilitating parts for an archery riser and an automotive ECU housing.

The Universal Co-bots are collaborative robots that work safely alongside humans.  The robots themselves have sensors that detect when someone is near or approaching the robot, triggering the mechanism which slows down and stops the machine.  Chicago White Metal implemented four co-bots, which are currently handling parts for two different models of portable oxygen concentrators, a crossbow riser, an electronic housing, and a medical device handle.

Importance of Design for Manufacturing in Die Casting

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Before the Design for Manufacturing (DFM) process can begin, it’s essential to determine which manufacturing process will be the optimal solution for your final product. While several methods are available to manufacture parts efficiently, few offer the quality, environmental advantages, and cost savings of die casting.

Depending on the project’s specific needs, our team will work with a potential customer to determine if the part is a good fit for High-Pressure Die Casting. Some of these factors include:

  • Part specifications: The size and scope of your project are one of the first things taken into consideration – what size is it? What are the physical and cosmetic requirements?
  • Material: At CWM, we cast three alloys – Aluminum, Magnesium, and Zinc. Each has its own set of advantages, and our team can help determine which alloy might be the ideal choice for your component.
  • Project details: It is essential to provide as much detail as possible about your project to determine whether die casting is the right process for the application. Information such as the expected annual and lifetime quantity needed, where the part will be assembled, what mating parts are attached to it, will it be exposed to environmental extremes or chemicals, what other processes are being considered, etc. These are all important details to help determine if high-pressure die casting is a good fit.

Application Review

Once it’s determined that die casting is the right manufacturing process for your part, CWM will initiate DFM process with your team. It starts with a detailed application review – the more we know about your project, the better prepared we will be to make recommendations.

Our engineers must understand what the end product does and how the part being cast will function. Even the most minor details may affect cost and performance. Therefore, CWM’s engineers consider the following factors in the initial review:

  • Mating part review: What components or materials connect to this part? Where are the connecting surfaces?
  • Function: What are the features and functions of the part?
  • Product testing: Are there any additional tests the part needs to undergo (i.e., leak testing, stress tests, corrosion resistance)?
  • Finishing: Are there any cosmetic or finish requirements? What surfaces does the user view? What coating is being considered?

CWM welcomes video conferences throughout the process and encourages face-to-face meetings on-site at CWM, or we can arrange for our team to visit your location. A visit to CWM will allow both our team and your team to develop a partnership, review best practices, learn about the die casting process & other technologies used at CWM, and discuss the plans for the future.

Part Optimization

At CWM, a DFM review is part of every new project. As part of that review, we offer our customers a wide variety of design assistance. For example, we will work with you and your team to complete design conversions from injection-molded parts, other casting methods, or hogouts. Our team also assists with recommendations for appropriate design guidelines for all three alloy types, consolidating assembly components into a single die casting, and we always complete a mold flow analysis using Magmasoft® to ensure a quality casting.

In the preliminary stages of moving from concept to ready-to-tool design, a CWM product engineer will explore solutions that would be best for the part – this can include weight reduction or component consolidation. Then, CWM can work with your team through various designs until the part is optimized for our High-Pressure Die Casting process and your applications requirements.

We believe that a well-optimized part makes for an improved die cast process that can ultimately reduce part cost – which, aside from producing the best quality part possible, is the primary goal.

Contact CWM Today to Learn More

A good die caster will know whether a part is a fit for the die casting process. An excellent die caster will have enough experience to direct you and your team towards another approach if die casting is not a good fit and the expertise to help convert your part to a High-Pressure Die Casting that maximizes overall performance and value.

Contact our team today for more information on how Design for Manufacturing can benefit your project during the die casting process. Email sales@cwmtl.com or call 630-595-4424. You can also Request a Quote using our online form, and a member of our team will reach out to you directly.

Inside CWM Winter 2021/22 – Vol. 17 No. 3

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In the Winter 2021/22 edition of Inside CWM you can learn about:

  • Opportunities provided to Harper College Students through the CWM Scholarship Program.
  • How CWM is going to leverage technology/automation for the future.
  • Find out who won CWM’s Outstanding Performer’s of the Month for all of 2021 and see who was our Outstanding Performer of the Year!
  • See who celebrated a milestone tenure at CWM with our Service Awards!
  • Welcome “new” CWM employees who were brought on full-time from various staffing agencies.
  • CWM Gives Back 2021: Toys for Tots
  • Finally, get Turkey Tips from CEO Eric Treiber and check out some Throwback CWM pictures!

Click here to read Inside CWM: Winter 2021/22

Quick Contact

Call +1 630-595-4424 or fill out the form below for more information.

Delivering precision Die Cast products and services in Aluminum, Magnesium and Zinc since 1937.

Contact us

  • 649 IL Route 83, Bensenville, IL 60106-1340
  • +1 630-595-4424
  • +1 630-595-4474

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