The term general casting can mean different things in different industries. In entertainment, it refers to auditions, but in manufacturing it describes the family of processes where molten metal is shaped into parts. For buyers, general casting covers everything from low-cost sand molds to high-precision aluminum die castings.
In this article, we’ll explain the main casting processes and their variations, review tolerances and how they are calculated, outline common casting defects, and show why aluminum die casting is one of the most effective solutions for demanding applications.
What Is General Casting in Manufacturing?
In manufacturing, general casting is the umbrella term for all processes that pour or inject molten metal into a mold. Depending on the process, it can produce:
- Rough, large-scale structural parts (sand casting)
- Precision, high-volume components (die casting)
- Complex near-net-shape parts (investment casting)
General casting remains widely used because it supports complex geometries, reduces machining, and scales well from prototypes to mass production.
Common General Casting Processes and Variations
1. Sand Casting
- Flexible and low-cost, suitable for large components.
- Variations: green sand casting, resin sand casting, shell mold casting.
2. Investment Casting
- Also known as lost-wax casting.
- Excellent for complex geometries and thin-walled parts.
- Variations: ceramic shell casting, plaster mold investment casting.
3. Die Casting
- Metal is injected into steel molds with pressure.
- Variations include:
- High Pressure Die Casting (HPDC): fast, precise, widely used in automotive and electronics.
- Low Pressure Die Casting (LPDC): slower but with good feeding and less porosity.
- Gravity Die Casting: uses gravity to fill metal molds, suitable for medium runs.
- Vacuum Die Casting: reduces air entrapment, improves mechanical properties.
- Squeeze Casting: combines forging pressure with die casting, creating dense, strong parts.
4. Other Casting Methods
- Centrifugal casting, continuous casting, lost foam casting—used in specific industries.
Die casting (especially HPDC and vacuum die casting) offers the best balance of precision, speed, and cost efficiency.
Casting Tolerances in General Casting
Casting tolerances define how close a part is to its design dimensions. These tolerances depend on both the casting process and the buyer’s drawing requirements.
- Sand casting: ±0.5–3.0 mm, depending on size.
- Gravity / Low-pressure die casting: ±0.1–0.5 mm.
- High-pressure die casting (HPDC): ±0.05–0.2 mm, excellent repeatability.
- Investment casting: as tight as ±0.1 mm.
👉 Buyers should expect suppliers to review the drawing and confirm which tolerances are achievable. At Yongzhu Casting, we provide a 48-hour DFM review to flag tolerance risks early and avoid costly redesigns later.
Common Defects in General Casting and How to Prevent Them
Casting defects can affect performance, sealing, and appearance. These are the most common:
Shrinkage and Porosity
- Casting shrinkage / solidification shrinkage / linear shrinkage – solved with riser design and process control.
- Casting porosity / gas entrapment – reduced with vacuum die casting and resin impregnation.
Cracking and Distortion
- Hot tearing / hot cracking – controlled with proper gating and alloy selection.
- Residual stress / warpage / heat treatment distortion – minimized by controlled cooling and stress relief.
Filling and Surface Defects
- Cold shut / misrun – prevented by correct melt temperature and gating design.
- Oxide inclusions – avoided with filtration and degassing.
- Surface roughness / flash removal – improved with finishing and precise tooling.
Design Factors Affecting Defects
- Draft angle – ensures easy part release without surface tearing.
- Riser design and efficiency – critical for feeding molten metal and avoiding shrinkage cavities.
- Machining allowance – ensures surfaces meet final tolerance after finishing.
- Grain refinement – improves strength and fatigue life.
At Yongzhu Casting, we combine mold flow simulation, CMM inspection, and pressure testing to catch and correct these risks before shipment.
Why General Die Casting Is the Preferred Solution
While all processes fall under general casting, aluminum die casting is often the most practical choice for modern industries:
- High strength-to-weight ratio – essential for automotive, aerospace, and marine parts.
- Corrosion resistance – anodizing and powder coating protect against salt spray.
- Dimensional accuracy – meets tight tolerance requirements for housings and brackets.
- Mass production efficiency – ideal for OEM suppliers.
Why Work With Yongzhu Casting?
At Yongzhu Casting, we focus on precision aluminum die casting, backed by 20+ years of manufacturing experience.
- Comprehensive processes: HPDC, LPDC, vacuum die casting, squeeze casting, and gravity casting.
- Engineering support: DFM feedback within 48 hours.
- Quality testing: CMM inspection, salt spray, and pressure testing.
- Global supply: Serving automotive, marine, and industrial customers worldwide.
Conclusion
General casting includes many methods, each with strengths and limitations. For buyers who need reliable, high-volume, and corrosion-resistant components, aluminum die casting remains the most effective option.
📩 Send your drawings today to yongzhucasting@gmail.com for a free feasibility review or quote.
