Advantages of Investment Casting Over Traditional Machining

Investment casting is rapidly becoming the preferred manufacturing method over conventional CNC machining, especially for low to medium production volumes. In this article, we’ll explore the key advantages of investment casting compared to machining from solid metal, also known as hogging out, and why it’s often the smarter choice in terms of cost, design flexibility, material selection, and production speed.

1. Cost-Effective and Efficient Manufacturing

Myth: Machining is cheaper for small runs.
Reality: It often costs more.

When machining from solid billet, 50% to 90% of the material is typically removed and discarded as scrap. That’s a significant cost, especially with high-value metals like stainless steel, aluminum, CNC machine time, tooling wear and replacement, skilled labor costs, and cobalt alloy.

The total expense can far exceed the price of a precision-cast component.

Investment casting, especially when using 3D-printed rapid prototype patterns, drastically reduces waste. At Barron Industries, we produce small-batch castings (1–10 pieces) in as little as four weeks, offering a more economical and timely solution.

2. Greater Design Flexibility

Early involvement with your metal casting supplier can unlock design possibilities that machining simply can’t deliver. Complex internal geometries, such as:

• Volute sections in pump housing
• Curved impeller blades
• Intricate flow paths

These features are nearly impossible, or prohibitively expensive, to machine from a solid block.

With investment casting and 3D printed patterns, engineers and designers have far more creative freedom without compromising manufacturability or performance. This is especially advantageous for applications like military castings, aerospace castings, and automotive castings, where design complexity meets performance demand.

3. Lightweight, High-Performance Components

Designing for casting enables net shape production with thin walls and minimal secondary machining. This can reduce component weight by 50% to 80% compared to parts machined from plate, block, or bar stock.

Lightweight parts are especially critical in aerospace, defense, and automotive applications, where every ounce counts. For aerospace suppliers and OEMs, these weight savings can translate to increased fuel efficiency and enhanced performance.

4. Broader Material Selection

Machining is limited to materials available in wrought form, which restricts your options. Investment casting unlocks a vast range of ferrous and non-ferrous alloys.

At Barron Industries, we pour over 200 unique alloys, including:

• 4140 and 4318 steel (not typically available in bar form)
• Precipitation hardening stainless steels (13-8, 15-5, 17-4)
• High-strength aluminum (A357, A206)
• Nickel-based alloys, cobalt-based alloys, and more

This flexibility allows you to match material properties to your exact performance requirements.

5. Stronger, More Functional Designs with Fab-to-Cast Conversion

When low-volume components are fabricated by welding plates or machining individual parts, strength and precision are compromised. Converting fabricated parts to precision castings offers:

• Improved structural integrity
• Fewer assembly points (reducing potential failure)
• Easier incorporation of complex features (e.g., lightning holes, curves, fine contours)

With rapid prototype casting, we replicate the design with the intent of a weldment, but in a single, stronger, and more reliable part.

6. Faster Prototyping and Scalable Production

In industries like defense and aerospace, production often occurs in phases:

• EMD (Engineering & Manufacturing Development)
• Validation builds
• LRIP (Low-Rate Initial Production)
• FRP (Full-Rate Production)

Barron Industries supports each phase by:

• Delivering 1-piece prototype castings in weeks
• Validating form, fit, and function
• Scaling to full production with minimal lead time

Casting allows manufacturers to iterate designs faster and transition to production seamlessly, reducing development risk and improving time-to-market.

Why Choose Barron Industries for Investment Casting?

Barron Industries combines engineering expertise, in-house 3D printing, CNC Machining and rapid prototyping capabilities to help customers turn complex ideas into high-performance components, faster and more cost-effective than traditional machining.

Let’s Talk About Your Next Project

Considering switching from machining to casting? Contact us today to learn how our investment casting solutions can help reduce costs, increase design flexibility, and speed up production.