Aluminum sand cast tooling costs from $400 to $6,500 depending on size and complexity of the aluminum casting part life is 5,000 parts. Aluminum die casting tooling costs from $4,000 to $65,000 depending on size and complexity of the aluminum die cast part. However, tooling insert life is 100,000 parts and can be as much as 1,000,000 high pressure die casting parts.
The break-even point from aluminum sand casting to aluminum die casting varies from a few hundred to a few thousand parts. This cost is determined by the cost of tooling and the amount of machining required from the aluminum sand casting process that is not required as an aluminum die casting because of the tighter tolerances of the aluminum die cast process in making casting parts.