| Sand Casting | Die Casting |
|---|
| 1) Best for producing medium to large-sized casting. | 1) Best for manufacturing small-sized casting. |
| 2) Lower dimensionally accurate casting with inaccurate tolerance can be produced. | 2) Greater dimensionally accurate casting with close tolerance can be produced. |
| 3) Cost-effective mould-making process as low-cost sand is used. | 3) Making a mould is costly and only justified if products are to be mass-produced. |
| 4) The conventional process is more labour-intensive, and the end casting result still depends upon the skill of the operator. | 4) The non-conventional process is less labour-intensive, and end-casting results do not depend upon the skill of the operator. |
| 5) Difficult to produce products with less thickness and higher draft angle. | 5) Easy to manufacture products with less thickness and higher draft angle. |
| 6) The surface finish achieved is lower than die casting because of course sand. | 6) The surface finish achieved is better than sand casting as metal is used as a die. |
| 7) Suitable for small volumes of casting products, as the production cycle time is longer. | 7) Suitable for large volumes of precise casting products as the production cycle time is shorter. |
| 8) Mould is made from sand, silica, and moisture is prone to casting defects such as blowholes, mould wash and mould drop defects etc. | 8) Casting defects related to moisture are negligible in die-casting process. |
9) Higher secondary manufacturing processes are required because of sand moulds.
| 9) Fewer secondary manufacturing processes are required as the die mould gives better castings. |
| 10) Sand casting process has downtime between casting production as the mould needs to be broken and made again. | 10) Downtime here is less as the die mould can be used for multiple cycles as compared to the sand casting method. |
| 11) External pressure is not used in this process; molten metal flows in all sections of the mould through gravity. | 11) External pressure is used to force the metal into the die mould cavity and all sections of the die. |
| 12) Suitable for production casting components from ferrous and non-ferrous metals. | 12) Best for non-ferrous metals only. Die cannot handle high-temperature ferrous metal. |
