Technologies
The metal casting process is a manufacturing method in which molten metal is poured into a mold cavity shaped to the desired part geometry. After cooling and solidification, the mold is removed to ext
The metal casting process is a manufacturing method in which molten metal is poured into a mold cavity shaped to the desired part geometry. After cooling and solidification, the mold is removed to extract the finished casting. It produces complex shapes in metals like aluminum, iron, and steel acros
The metal casting process is a manufacturing method in which molten metal is poured into a mold cavity shaped to the desired part geometry. After cooling and solidification, the mold is removed to extract the finished casting. It produces complex shapes in metals like aluminum, iron, and steel across automotive, machinery, and industrial equipment applications.
Sand casting remains the most widely used method in Egyptian foundries, achieving ±1.0–1.5 mm tolerances (ISO 8062-3, Grade CT8–CT10) and surface finishes of Ra 12.5–25 µm. It suits large parts and low-volume production without expensive tooling.
Die casting uses high-pressure injection into steel molds, delivering ±0.1–0.3 mm tolerances (CT5–CT7) and Ra 1.6–3.2 µm finishes. AlSi9Cu3 aluminum is the standard Egyptian die-casting alloy for automotive and pump housings.
Investment casting achieves ±0.1–0.5 mm tolerances with Ra 1.6–3.2 µm finishes, excelling at complex geometry and fine detail. It dominates aerospace and medical component production globally.
Shell moulding bridges sand and die casting: ±0.5–1.0 mm tolerances, Ra 3.2–6.3 µm finishes, suited to medium-complexity parts at moderate volumes.
| Casting Type | Typical Tolerance | Surface Finish (Ra) | Best For | Typical Lead Time |
|---|---|---|---|---|
| Sand Casting | ±1.0–1.5 mm | 12.5–25 µm | Large parts, low volume | 1–4 weeks |
| Die Casting | ±0.1–0.3 mm | 1.6–3.2 µm | High-volume, thin-wall parts | 2–6 weeks (tooling) |
| Investment Casting | ±0.1–0.5 mm | 1.6–3.2 µm | Complex geometry, small parts | 2–5 weeks |
| Shell Moulding | ±0.5–1.0 mm | 3.2–6.3 µm | Medium complexity, medium volume | 1–3 weeks |
| CNC Machining (Entag) | ±0.05 mm | 0.8–1.6 µm | Precision parts, low-medium volume | 3–7 days |
For parts requiring tighter tolerances than casting can deliver, Entag's CNC machining achieves ±0.05 mm with no tooling cost.
Casting involves significant tooling costs (molds, patterns, fixtures) — $2,000–$50,000+ depending on complexity — making it uneconomical for single pieces or small batches. CNC machining eliminates tooling altogether.
Casting cannot reliably achieve tighter than ±0.05 mm tolerances without post-machining. If your part requires Ra 0.8 µm surface finish or tolerances under ±0.1 mm, CNC finishing is mandatory. Many engineers choose to machine from solid rather than cast and then finish.
Lead time matters. Casting requires 1–6 weeks for tooling and production. Sheet metal fabrication and CNC machining at Entag deliver quotes in 24 hours and parts in 3–7 days. For urgent prototypes or low-volume runs, machining is faster and cheaper.
What is the metal casting process?
The metal casting process shapes molten metal by pouring it into a mold cavity, cooling it to solidify, and extracting the finished part. It creates complex geometries that would be difficult or expensive to machine. Casting dominates volume production of automotive housings, machinery frames, and industrial equipment worldwide.
What are the main types of metal casting?
The four most common types are sand casting (large, low-volume parts with ±1.0–1.5 mm tolerance), die casting (high-volume, thin-wall parts with ±0.1–0.3 mm tolerance), investment casting (complex small parts with ±0.1–0.5 mm tolerance), and shell moulding (medium-complexity parts with ±0.5–1.0 mm tolerance). Each differs in tooling cost, lead time, and precision capability.
What tolerances does metal casting achieve?
Sand casting typically achieves ±1.0–1.5 mm (ISO 8062-3, Grade CT8–CT10). Die casting achieves ±0.1–0.3 mm (CT5–CT7). Investment casting achieves ±0.1–0.5 mm. For tighter tolerances (±0.05 mm), post-casting CNC machining is required on functional surfaces. At Entag, we achieve ±0.05 mm directly, with no mold cost.
What is the difference between casting and machining?
Casting solidifies molten metal in a mold — best for complex shapes and volume production. CNC machining removes material from solid stock — best for tight tolerances (±0.05 mm), fine finishes (Ra 0.8 µm), and low-volume runs without tooling expense. Many parts use both: cast near-net shape, then CNC finished.
What are common casting defects?
Shrinkage porosity (voids from uneven cooling), cold shuts (incomplete fusion of metal flows), misruns (incomplete mold fill), and surface roughness are the primary defects. Defects increase when pouring temperature, gating design, or mold venting are incorrect. Post-cast inspection and X-ray testing are standard in industries like aerospace and automotive.
What are my alternatives to metal casting in Egypt?
Foundries operate across Cairo, Alexandria, and 10th of Ramadan City. However, for precision parts, fast turnaround, or small volumes, CNC machining and sheet metal fabrication are faster and cost-effective — with no tooling investment. Entag delivers quotes within 24 hours.
Ready to start your project? Request a quote on Entag — upload your CAD file and get a price in 24 hours. Whether your part was designed for casting or machining, we deliver precision metal components across CNC machining, sheet metal fabrication, and 3D printing — no mold cost, no minimum order.
