Permanent Mold Casting Size Capabilities

Is my design too big or too small for permanent mold casting?

Permanent mold casting maximum and minimum size capabilities depend on part weight and dimensions.

While each foundry’s capabilities are different, BPI permanent mold castings are typically 1 to 100 pounds, with length, width, and height dimensions less than 50 by 50 by 18.75 inches.

Dimensions

Maximum size capabilities depend on the foundry’s equipment. Each foundry and casting process is different.

At Batesville Products, we do permanent mold casting. This means the mold (aka the casting footprint) must fit on a tilt pour or reverse tilt pour machine.

The maximum mold size our largest press can hold is 50 inches by 50 inches with a maximum cavity depth of 18.75 inches. The casting must fit inside this mold. However, we can get creative to accommodate different sizes.

Image: Tilt pour press and furnace.

Very Big Castings

For very large parts, consider sand casting. The sand casting process does not use a tilt pour press, so mold sizes are not as constrained.

Very Small Castings

For very small parts, consider investment casting. Investment casting is common for tiny and intricate pieces, like jewelry.

Weight

Because the tilt pour method minimizes metal turbulence, the permanent mold process produces very dense castings. Permanent mold castings are typically denser than static poured sand castings and high pressure injected die castings.

BPI permanent mold aluminum castings are roughly 1 to 100 pounds (with a few outliers). Since aluminum is so lightweight, this means some pretty large castings!

Maximum weight limits again depend on foundry equipment and operations. Can the tilt pour press handle the weight of the casting, extra gating material, and steel mold? Can the operators pour enough metal into the mold before it freezes off?

Reducing Casting Weight

Permanent mold castings must have at least 0.18 inch wall thickness to ensure proper metal flow. If you’re looking to reduce the weight of your casting, read this guide.

Secondary Operations

Secondary operations may also determine casting size limitations. Do you need CNC machining? If so, does the casting fit inside the supplier’s CNC machine? How will that size of casting be fixtured for CNC machining?

If you’re using one full-service supplier for casting and machining (like Batesville Products) then you don’t have to worry about this. However, if you are quoting different suppliers for each operation, make sure your product is compatible with their equipment.

Summary

Overall, maximum and minimum sizes depend on the foundry. Permanent mold casting size limitations depend on weight and dimensional fit on foundry equipment.

At Batesville Products, we specialize in moderate sized castings, typically 1 to 100 pounds, smaller than 50 inches by 50 inches by 18.75 inches. Contact us today to learn more.