1 Which metal do you pour?

The question isn’t just asking a metalcasting facility if it pours aluminum or iron. What type of iron? Not all iron is equal. Do you need gray, ductile or malleable iron? What range of aluminum alloys?  If the metalcasting facility pours more than one metal type, which type do they pour the most? If you need a special alloy that it only pours once a month, you might not want to select that facility. 

A metalcasting facility’s mix of alloys is selected and tailored specifically to the equipment and processes in place. Asking a plant that pours primarily ductile iron to switch to gray iron for your part is not a seamless process. You’ll likely receive a no-quote or an expensive quote.  

2 What is your casting size range?

Most metalcasting facilities are set up for a certain size casting. Some have equipment for small castings, in the range of 1 to 15 lbs. Others may pour up to 50 lbs., or in a range of 50 to 200 lbs. A metalcasting facility that performs floor molding can make castings in the thousands of pounds, but probably won’t quote a 5-lb. casting. 

Most plants have the equipment for a specific range of sizes. For instance, on a matchplate molding line, the plant is constrained by the dimensions of the matchplate. Diecasters are constrained by their platen size. Facilities are also constrained by the size of their furnace—meaning how much metal they can melt at a time, as well as their equipment and tools used in secondary processes, such as grinding and machining. 

3What is your minimum order quantity?

Some metalcasting facilities specialize in either low-volume or high-volume production. Some offer both. Most customers want to reduce inventory and order quantity. Awarding a lower volume part to a higher volume metalcasting facility could result in longer lead times and higher quotes.

Equipment designed to produce molds at high speeds for high-volume production are most efficient when running constantly without many pattern changes. A pattern set up and change to insert one of your low volume jobs results in lost molding time on the equipment and a cost to the metalcasting facility. This cost may be passed on to you through setup fees. It’s best to select a casting facility that is designed for the volumes you have in mind.

4 Are you capable of producing complex castings?

If your casting is complicated, does the metalcasting facility have experience with similar castings? Engineered castings are more than a lump of metal. Metalcasting is a shaping process on a specific metal that results in specific properties. The process affords you the ability to let your imagination loose for shapes and internal features, but it is important to verify the metalcasting facility you plan to work with has the capabilities to achieve your specifications, such as surface finish, properties, and dimensional stability. 

Also, be wary of being the experimental guinea pig for a supplier’s first stab at a new service or process, unless you have the time and desire to be part of the development.

5 What is your production lead time?

Casting buyers should ask, “If I place an order, when are you going to make my parts?” It’s a fair question to ask, along with if the given lead time will be the same whether the supplier is busy or slow. You want to find a supplier that offers a lead time that matches up to the lead times you give your customers. 

A buyer also might ask what the lead times are on specific molding lines or casting cells within the plant, as production rates may differ line to line, machine to machine.

Perhaps most importantly, you want to know what the communication methods are for when a delivery date will be missed. When will you find out? Two weeks before the scheduled date or only after the date has passed? 
6
What value-added services can you provide? 

Metalcasting facilities may offer a range of in-house services that fits their target niche of casting jobs. This can include heat treating, inspection, warehousing, painting/coating, plating, or subassembly. If your casting requires any special secondary processes, it’s worth asking to see if those could be covered by the casting supplier. It will save you time and logistics management. If the metalcaster subcontracts the work to a machine shop, paint shop, etc., ask to have that information. You might not speak directly with the subcontractors, but it’s good practice to know who they are. 

7 How can you assure me of good quality?

When you ask about quality, remember that what you are really asking is if the casting supplier will adhere to your specifications. You want to make sure the supplier can deliver the part that meets your requirements, which will be different than those in other segments or applications. If something measurable, like a consistent casting weight, is important to you, you’ll want to ask if the supplier can give data showing it can achieve the appropriate consistency part to part. 

If you can, visit the plant before you start doing business and review internal documents. What’s the scrap rate and scrap rate goal? What is their rate of returns from customers? What kind of controls are being used on the equipment in the shop floor? Is the plant operating within the parameters it has set up in its controls? Do those parameters fit your needs?

8 How do I know I’m getting the best overall price? 

Metalcasting facilities with efficient processes that best match your part should result in a fair price. Ask what technology the plant uses to be cost competitive. Does it have any automation, such as in grinding, material handling or high speed molding? Is the part flow through the plant direct without crisscrossing the buildings? Are parts well tracked throughout the process steps? 
What is the product mix the metalcasting facility is producing currently? Are they similar to yours in size, complexity, and volume? That’s a good indicator you are in a plant best suited to your particular needs, which will result in a more favorable cost. If your part seems like the odd duck, you likely will incur higher costs as the metalcasting facility attempts to fit your square peg in a round hole. 

Additionally, as a customer, remember to consider all the costs associated with the part when determining best overall price. Included in this calculation should be value-added services, inventory costs, surcharges, packaging, price of certification, transportation/shipping, and the risk associated with a missed shipment. 

9 I have a tool/pattern— can you use it?

In metalcasting, tooling and patterns are made for the specific equipment on which the molds or castings will be produced. If you have pattern and hope to use it at a different supplier, your best bet will be to find a supplier that uses that same molding machine as the original supplier. Sometimes a metalcasting facility can rework a die or pattern to fit a different machine, but depending on the complexity, the cost to do this can be almost as much as making a new pattern.

A metalcasting facility also may prefer to use tooling it has created because it can take responsibility for the quality of the castings. The cost estimator will have more confidence in the quality of the parts produced on the company’s own die or pattern and provide a quote accordingly. With someone else’s tooling, unknown variables, such as how much grinding would be needed in finishing, will result in a more expensive quote.  

10 Is your business profitable?

Just as a potential casting supplier will be interested in your company’s finances, you’ll want to know if the metalcaster is a healthy business. Finding and changing suppliers is difficult and you want to avoid investing money and resources in a supplier that will be closing in a year. Plus, a shop that is not profitable could raise prices six months after the tooling is built to stay afloat.
Be direct. Most metalcasting facilities will be fairly open with providing some financial information when you ask. You also may want to run credit reports or check credit references. 

If you want more proof, plan a site visit to check if it passes the “sniff test.” Is maintenance and housekeeping kept up? Have they invested in updates to equipment recently? What investments are being planned for the next five years? Is the plant operating at least five days a week? These are all signs a metalcasting facility is profitable.