How to estimate your investment casting costs?

Investment casting is one of the most common methods of casting components in automotive, industrial and railway applications. Since different factors can affect investment casting costs, the best way to estimate casting costs is to outline the major factors that will affect the total cost. These different factors will affect each project differently. A better understanding of the foundry's production process is critical to your ability to estimate the cost of investment cast parts.

1. Main material cost - metal

The cost of primary materials (especially metals) is often the major expense in the production of investment cast parts. Considering the casting process, the weight of the metal material used is always greater than the final size of the product. Therefore, the design of the casting pour is crucial, as material waste in the casting and subsequent finishing stages can further increase the overall casting cost.

Design engineers help determine metal selection based on the casting's end use. Investment casting costs per kilogram are determined by the prices of metals such as stainless steel, iron, aluminum and specialty alloys. These materials are selected for their specific properties to meet the stringent standards required by various industries. However, its market price will fluctuate due to factors such as supply and demand balance, global economic conditions and resource availability.

Some metals are more expensive than others. For example, titanium is more expensive than aluminum. Working with a casting consultant to develop an effective project plan is critical to investment casting cost calculations.

2. Investment casting design cost

Design complexity also has a major impact on investment casting costs. Complex structures may require some additional procedures and processing. This will also further increase the price of investment casting products.

When designing a casting process, our engineers consider two main types of costs to reduce overall costs:

· Direct material costs: Made up of the materials used to make the product, such as cast metals or alloys, typically broken down into recycled steel, non-ferrous metals and rare metals.

· Indirect material costs: This includes optional cores, molding sand, investment casting mold costs, etc.

3. Investment casting product output cost

Casting yield plays a vital role in determining the cost-effectiveness of the investment casting process. Essentially, casting yield is the ratio of the weight of the final usable cast product to the total weight of the metal poured (including product, gates, runners, and any scrap). Higher casting yields indicate more efficient use of materials, resulting in less waste and lower material costs.

When casting yields are low, it means that a larger proportion of the material does not contribute to the final product and instead becomes waste. This scrap still incurs costs in terms of sourcing, melting, and processing, resulting in higher overall investment casting costs. Therefore, when the yield is lower, the cost per kilogram of the final product increases.

Typically products with complex structures may have lower yields. Therefore, increasing production yields can result in significant cost savings, especially if initial production volumes are low. Experience in specific industries and product types can significantly reduce casting costs for an investment foundry.

4. The number of shells will also affect investment casting costs.

The number of shells in investment casting is another important factor that affects the cost of the process. In investment casting, a ceramic shell is built around a wax pattern to form the mould. The complexity and size of the final product determines the number of layers or shells required to achieve the desired mold thickness and strength.

Increasing the number of shells has a direct impact on the overall cost of investment casting for several reasons:

Material costs: More shells mean more ceramic material. The materials used to make these enclosures often include high-grade refractory ceramics and can be very expensive. As the number of enclosures increases, the material cost increases proportionally.

Labor and Time: The process of applying each layer of crust is meticulous and time-consuming. More layers not only increase the direct labor involved but also lengthen the total production time. This can result in higher labor costs and lower overall productivity.

Energy consumption: Each layer of shell needs to dry and cure properly before the next layer can be applied. This step usually requires heating and maintaining specific environmental conditions. Therefore, more shells mean higher energy consumption during the drying and curing stages.

However, it is also important to note that the number of enclosures usually depends on the complexity and requirements of the final product. While fewer enclosures can reduce costs, they still must provide sufficient strength and detail to meet product specifications. Large metal investment castings generally require three or more layers. Striking the right balance between mold quantity and cost considerations is critical to optimizing the investment casting process, ensuring the quality of the final product and cost-effective production.

5. Labor costs of precision investment casting

Any investment casting business should add a labor cost estimate when calculating the total cost of investment casting. The average investment casting worker salary also has a huge impact on lost wax casting cost estimates.

Traditionally, the investment casting mold making process, metal pouring, and sand mold removal processes have been labor-intensive. However, modern equipment and technology have helped automate some processes to reduce manual labor and eliminate human error. While we cannot remove labor costs in the investment casting cost calculator, some foundries can reduce this cost.

6. Investment casting mold cost

The cost of investment casting molds (especially those used to create wax patterns) is an important consideration in the casting process due to a number of factors.

These molds are typically made from aluminum or other durable materials and require precision engineering to produce highly detailed and accurate wax patterns, which directly affects the quality of the final casting.

The complexity of the mold design, the number of cavities (which determines throughput), and the life of the mold itself all affect the initial investment. Additionally, the technical expertise required to design and machine these molds adds to the overall cost.

While the upfront cost of these molds can be high, their ability to produce complex parts with high repeatability and minimal material waste often justifies the investment, especially in large-scale or continuous production scenarios.

7. Investment casting and sand casting costs

Investment casting and sand casting are two important casting methods, each with different cost implications.

Investment casting is known for its ability to produce highly detailed and complex parts with excellent surface finishes. However, it is more costly due to the materials (such as specialized ceramics used for the molds) and the labor-intensive steps involved (such as creating precise wax models and multiple ceramic shell layers).

Sand casting, on the other hand, is more cost-effective for larger volumes and larger parts, primarily because its mold-making process using sand is simpler and reusable, reducing material and labor costs. However, it often results in a rougher surface finish and may require additional machining and finishing work, which increases the overall cost.

The choice between the two methods usually depends on the specific requirements of the project, including level of detail, throughput, material specifications, and cost constraints.

In conclusion

The above is our approach to estimating investment casting costs per kilogram, but this result will vary based on different industries and project needs. Therefore, if you want to know exactly how much investment casting costs per kilogram in an investment foundry, it is best to consider the relevant factors individually and consult a professional advisor before calculating!