| Feature | Aluminum Gravity Die Casting | Aluminum Sand Casting |
| Mold Material | Permanent mold made of metal (typically steel or cast iron) | Temporary mold made of sand and binder |
| Initial Tooling Cost | High (due to the durable metal mold) | Low to moderate (sand molds are less expensive to produce) |
| Lead Time | Longer (due to the time needed to create the metal mold) | Shorter (sand molds are quicker to prepare) |
| Production Volume | Economical for medium to large production runs | Suitable for low to high production volumes |
| Dimensional Accuracy | Higher (tight tolerances and more consistent dimensions) | Lower (more variability and less precise) |
| Surface Finish | Better (smoother finish, less post-processing required) | Rougher (may require more machining and finishing) |
| Mechanical Properties | Better (denser and stronger due to controlled cooling) | Lower (more porous structure and potential for weaker properties) |
| Complexity of Design | Moderate (can produce complex shapes but with some limitations) | High (can accommodate very intricate and complex designs) |
| Production Rate | Slower (due to manual pouring and cooling processes) | Faster (can use automated processes for high volumes) |
| Defects | Lower (less porosity and fewer defects due to controlled process) | Higher (more prone to defects like porosity and inclusions) |
| Material Range | Limited (primarily used for aluminum and certain other alloys) | Broad (can use a wide variety of metals and alloys) |
| Recyclability | High (aluminum and metal molds are recyclable) | High (sand can be reused and aluminum is recyclable) |
