Metal casting and metal fabrication are two broad terms in manufacturing that are often discussed together. Although closely related, they have different purposes, including different techniques, and are used in different ways by custom sheet metal fabrication services.
It is unsurprising to see questions like “Is metal casting a kind of metal fabrication?” The answer is not that direct, and we explored the relationship between both processes so you can know how they work.
What’s the Relationship Between Metal Casting and Metal Fabrication?
The main relationship between metal casting and metal fabrication as used by any sheet metal fabrication shop or rapid prototyping company is the use of metals. On the one hand, metal casting is a set of techniques with a general template of pouring molten metal into a predesigned mold, allowing it to cool to create a desired shape.
In contrast, metal fabrication is a set of techniques for refining a metal part or blank into final products. Some sheet metal custom fabrication services consider metal casting a specific process within a broad metal fabrication field. However, since not all metal fabrication processes involve casting except advanced metal fabrication, this might be incorrect.
In summary, the relationship between the two types of metalworking processes lies in their shared goal of producing metal parts. However, they are different in terms of techniques and applications.
Understanding Metal Casting
Metal casting is one of the oldest manufacturing processes, dating back thousands of years. It is a broader term for a set of techniques with a general template of pouring molten metal into a predesigned mould, allowing it to cool to create a desired shape. The mechanism of pouring the metal, mould, or other process during the cooling, however, leads to different types highlighted below:
Die Casting
Die casting is the most common metal casting technique because of the final part’s surface finish and dimensional accuracy. It involves pouring the molten into a CNC machined mold made from aluminum or steel. Die casting is compatible with metals like aluminum, zinc, and magnesium and is integral to the automotive, aerospace, and consumer electronics industries.
Sand Casting
Sand casting is a traditional casting method that uses a sand mold, unlike the die casting method. Hence, it is cheaper and can easily be formed around complex shapes. Additionally, it is a cost-effective option, especially when producing large components. Nevertheless, its disadvantages include a matte surface finish
Sand casting is a versatile technique compatible with iron, steel, aluminum, and bronze. Furthermore, it is a common method among metal fabricators working in the automotive, construction, and heavy machinery industries to produce parts like engine blocks, pump housings, and other large components.
Vacuum Casting
Vacuum casting involves pouring molten metal into a mold in a vacuum. As a result, this eliminates air bubbles and ensures a precise and quality finish. The casting technique can create parts with fine details and thin walls. Hence, it is applicable to prototyping medical devices and other parts with complex designs.
Gravity Casting
Gravity casting is another precision casting technique. It relies on the natural force of gravity in mold filling instead of external pressure, as in die casting. It is applicable in the production of medium—to large parts like engine components and pipes.
Squeeze Casting
Squeeze casting combines the principles of casting and forging. After pouring the molten metal into the mould, it is subjected to high pressure to compact it and create dense, high-strength parts like automotive suspension and aerospace components using metals like aluminum and magnesium.
Understanding Metal Fabrication
All metal fabrication is a set of processes that involves working with solid metal sheets, bars, or tubes. Fabricators use methods like CNC machining, sheet metal fabrication, and 3D printing in industries such as construction, automotive, aerospace, and manufacturing.
Below are a few metal fabrication techniques:
CNC Machining
CNC (Computer Numerical Control) machining is an accurate metal fabrication process that includes several techniques. These techniques involve using computer-controlled machines to cut, drill, and mill metal into the desired shape.
The precision metal fabrication technique is precise, accurate, versatile, and suitable for creating parts with high dimensional tolerances, such as engine components and medical devices.
Sheet Metal Fabrication
Sheet metal fabrication is a set of techniques, such as cutting and bending, for producing finished products from flat metal sheets. These techniques can be used to fabricate metals of different types, from metal enclosures and brackets to complex assemblies like HVAC systems and automotive body panels. Sheet metal fabrication is known for its flexibility, allowing manufacturers to produce prototypes and large production runs.
Metal Casting in Fabrication
Metal casting is also a part of the broader metal fabrication process when used with other methods. For instance, cast parts may undergo further machining, welding, or assembly during fabrication to achieve the final product.
This integration complements casting and fabrication. The casting process creates complex shapes, and metal fabrication refines such parts into complete products.
Conclusion
Metal casting and metal fabrication are closely related processes, as explained in this post. Understanding the relationship between both processes can help manufacturers choose the right method for their specific project.
In conclusion, metal casting is a part of metal fabrication, but it is just one of many methods used to shape and assemble metal into functional products. The choice between casting and other fabrication methods depends on factors like the properties of the final part, production volume, and cost considerations.
