| Factor | Permanent Mold Casting | Die Casting |
| Equipment Cost | Moderate | Highest |
| Casting Rate | 11 kg/hr (25 lb/hr) typical | 4.5 kg/hr (10 lb/hr) typical |
| Metal Cooling Rate | .3-1.0 C/sec (.5-1.8 F/sec). | 50-500 C/sec (90-900 F/sec). |
| Casting Size | Determined by machine size and die configuration | Determined by machine tonnage |
| Part Internal Shape | Cavities formed by metal cores with draft or sandcores for complex shapes with undercuts. | Cavities formed by metal cores with draft. |
| Gas Porosity | Best pressure techniques; low porosity possible with good technique. | Porosity may be present. |
| Minimum Wall Thickness | 4.0-7.0 mm (.188-.200 in.) required; 6.35 mm (.250 in.) normal. | 1.0-2.5mm (.100-.040 in.) depends on casting size. |
| Type Of Cores | Metal cores. Semi-permanent mold casting uses expendable cores. | Steel cores; must be of a simpler design and straight so cores can be pulled. |
| Achievable Tolerances | Best linear tolerance is 10 mm/m (10 mils/in.). | Best Linear tolerance is 4 mm/m (4 mils/in.). |
| Surface Finish | 4.0-10 um (150-400 uim.). | 1.5 um (50 uin.); best finish of the two casting processes. |
| Grain Size Dendrite-Arm Spacing Strength | Fine .03 -.07 mm (.001 - .003 in.). Excellent | Very Fine .005-.015mm (.0002-.0006 in.). Highest of the two casting processes. |
| Fatigue Properties | Good. | Excellent. |
| Wear Resistance | Good. | Excellent. |
| Overall Part Quality | Highest quality. | Tolerance and repeatability very good. |
