Casting Design Allowances: sand
Casting process design allowances — linear and volumetric shrinkage percentages, external and internal draft angles, minimum wall thickness, surface finish Ra, ISO 8062-3 dimensional tolerance grades (CT1-CT16), typical and maximum part weight ranges, relative cost, and production rate for 7 casting processes (sand, investment/lost-wax, die casting HPDC, permanent mold, centrifugal, shell mold, squeeze casting) across 11 alloy families (gray iron, ductile iron, carbon steel, stainless steel, aluminum A356/A380, copper alloys, zinc, magnesium, titanium Ti-6Al-4V, nickel superalloy)
| casting process | alloy family | dimensional tolerance grade achievable | dimensional tolerance grade typical | draft angle deg external (deg) | draft angle deg internal (deg) | linear shrinkage pct (%) | max practical weight kg (kg) | min wall thickness mm (mm) | notes | production rate parts per hour typical (parts/hr) | relative cost | surface finish Ra um typical (um) | typical lot size min (pieces) | typical weight range kg max (kg) | typical weight range kg min (kg) | volumetric shrinkage pct (%) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| sand | aluminum_A356 | CT10 | CT12 | 2 | 3 | 1.3 | 50,000 | 3 | A356-T6; low melting point aids surface quality; leaded sand gives Ra ~12.5 um | 8 | low_medium | 12.5 | 1 | 300 | 0.1 | 4.5 |
| sand | carbon_steel | CT12 | CT14 | 3 | 4 | 2 | 500,000 | 6 | 1020-1045 carbon steel; high shrinkage requires generous risers; resin sand tighter than green sand | 3 | medium | 25 | 1 | 1,000 | 0.5 | 6 |
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