Casting is a manufacturing process by which a molten material such as metal or plastic is introduced into a mold, allowed to solidify within the mold, and then ejected or broken out to make a fabricated part. Casting is used for making parts of complex shape that would be difficult or uneconomical to make by other methods, such as cutting from solid material. Casting may be used to form hot, liquid metals or meltable plastics (called thermoplastics), or various materials that cold set after mixing of components such as certain plastic resins such as epoxy, water setting materials such as concrete or plaster, and materials that become liquid or paste when moist such as clay, which when dry enough to be rigid is removed from the mold, further dried, and fired in a kiln.

Substitution is always a factor in deciding whether other techniques should be used instead of casting. Alternatives include parts that can be stamped out on a punch press or deep-drawn, forged, items that can be manufactured by extrusion or by cold-bending, and parts that can be made from highly active metals.

The casting process is subdivided into two distinct subgroups: expendable and nonexpendable mold casting.

Once used and cracked away, normal plaster cannot easily be recast. Plaster casting is normally used for nonferrous metals such as aluminium-, zinc-, or copper-based alloys. It cannot be used to cast ferrous material because sulfur in gypsum slowly reacts with iron. Prior to mold preparation the pattern is sprayed with a thin film of parting compound to prevent the mold from sticking to the pattern. The unit is shaken so plaster fills the small cavities around the pattern. The form is removed after the plaster sets.

Plaster casting represents a step up in sophistication and requires skill. The automatic functions easily are handed over to robots, yet the higher-precision pattern designs required demand even higher levels of direct human assistance.

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