Cost Comparison of Low Pressure, Gravity, and Differential Pressure Casting Molds

Cost Comparison of Low Pressure, Gravity, and Differential Pressure Casting Molds
The differential pressure of mold cost is higher than low pressure, and low pressure is higher than gravity, but the success or failure is determined by the full life cycle cost.
The magnitude difference of mold unit price
Taking passenger car wheels as an example, a single set of gravity molds costs about 60000 to 150000 yuan, low-pressure molds cost 180000 to 450000 yuan, and differential pressure molds are 15% to 25% higher than low-pressure molds.
The price difference comes from the complexity of the structure. Differential pressure molds need to withstand the pressure difference of the tank body, and require higher rigidity and sealing surface accuracy of the template.
The price difference of structural component molds is more obvious. The low-pressure mold for the subframe costs 400000 to 900000 yuan, while the gravity mold of the same size may only be half of it.
Unit cost is the benchmark for comparison
The mold cost needs to be amortized over individual items. When producing 100000 pieces per year, the mold cost of 300000 yuan is divided into 3 yuan per piece; When producing 3000 pieces per year, it is 100 yuan.
In addition to the mold, the production rate of the process also needs to be calculated. The proportion of sprues and risers in gravity casting is often 35% -45%, while in low-pressure casting it is about 25% -35%.
For every 10 percentage points difference in material utilization rate, the cost of a single piece of material will differ by about 8% -12%. This part is often overlooked.
The difference between energy consumption and labor
Low pressure casting requires a continuous insulation furnace for insulation, with a single unit power often ranging from 30-60kW. The annual electricity bill is a fixed expense.
Differential pressure casting also requires an increase in compressed air or inert gas consumption. The gas consumption cost is calculated based on the tank volume and the number of cycles.
Gravity casting equipment is simple, with low energy consumption, but requires high manual labor intensity. The difficulty of recruitment has become an implicit cost in some production areas.
Quality cost cannot be solely based on scrap rate
The scrap rate of gravity casting is often higher than that of low-pressure casting, especially on thin-walled parts. For every 1 percentage point increase in scrap rate, the cost per unit increases by approximately 1.5% -2%.
Low voltage components have better density and lower subsequent testing and repair costs. For safety components, this difference may exceed the price difference of the mold.
The quality advantage of differential pressure components is most evident in high-strength wheel types. On conventional wheel types, the premium of differential pressure is difficult to recover by quality.
Type change and flexibility
Gravity molds change quickly, usually within 0.5-1.5 hours. When there are multiple varieties and small batches, this advantage will be amplified.
Low pressure mold changeover takes 1.5-3 hours and requires takeover and machine adjustment. Frequent changes will eat up the beat advantage.
The change of differential pressure mold is the slowest, and the reset of the tank seal requires additional time. Suitable for large quantities of small varieties.
The pricing logic of Xinfeng Mold
For the same round, the quotations for the three processes will separately list the mold cost, trial mold cost, and recommended batch range, making it easier for customers to calculate according to the project.
This kind of listing is more useful than giving only a total price. The purchaser can use this to determine which process is more cost-effective in their own batch.
Unified caliber for quotation comparison
Before comparing prices, unify the specification sheet and clearly state the materials, coatings, and number of mold tests. The caliber varies, and the price difference is incomparable.
Converted based on the cost per unit. The mold cost divided by the batch size, plus materials and energy consumption, is the number that can be used for decision-making.
Frequently Asked Questions
Q: What is the price difference among the three types of molds?
Answer: Differential pressure is 15% -25% higher than low pressure, and low pressure is about 1 time higher than gravity.
Question: Should we only look at the mold price?
Answer: No, it should be calculated based on individual amortization and quality cost.
Q: What is the yield rate of gravity casting?
Answer: It is usually 55% -65%, with a high proportion of sprues and risers.
Q: Does low-pressure casting consume high energy?
Answer: Insulated furnaces typically have a capacity of 30-60kW and need to be included in the cost per unit.
Q: Which one to choose in small batches?
Answer: Gravity molds change quickly and are more suitable for small batches of multiple varieties.
Q: Can the premium of differential pressure be recovered?
Answer: High strength wheel types are acceptable, while conventional wheel types are more difficult.
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