How long do aluminum molds last?

If you’re investing in aluminum molds, you’ve probably wondered: will they last long enough to justify the cost?

Aluminum molds can last anywhere from 1,000 to over 100,000 cycles, depending on design, alloy, use conditions, and maintenance.

The lifespan of a mold isn’t a fixed number. It depends on how you use it. Let me explain what affects that lifespan and how aluminum compares to steel in performance.

What is the lifespan of aluminum molds?

Sometimes you need speed and low cost. That’s where aluminum molds¹ shine—but what’s the trade-off?

Aluminum molds generally last between 5,000 to 10,000 cycles for standard applications, but under ideal conditions, high-end aluminum alloys can achieve 100,000 cycles.

Aluminum molds are widely used for prototyping and low-volume production. The specific lifespan depends on various factors, including the aluminum grade (e.g., 7075 vs. 6061), mold complexity², cooling systems, and maintenance routines.

What affects the life of an aluminum mold?

There are a few major factors that influence mold lifespan:

When molds are used with non-abrasive plastics or waxes and stored correctly, they can exceed 50,000 cycles. But when used with high-temperature resins or reinforced plastics, wear can start to show quickly.

How long do casting molds last?

You might think casting molds are built to last forever, but are they really?

Casting molds can last from a few hundred to tens of thousands of cycles depending on mold material³, casting temperature, and alloy type.

Casting molds made of aluminum are ideal for non-ferrous metals and wax. But for high-volume die casting, steel or even cast iron is usually preferred. Still, with low melting point metals like zinc or aluminum, aluminum molds can be surprisingly durable if handled correctly.

Key differences between mold types

Let’s look at how long different mold materials tend to last in casting applications:

For small batch runs, aluminum casting molds are cost-effective and offer fast turnaround. That’s why I often recommend them to clients doing early-phase product development or limited production.

Are aluminum injection molds better than steel?

Steel molds are strong. But aluminum molds are fast. Which one should you choose?

Aluminum molds are better for fast prototyping⁴, low-volume production, and tight budgets, while steel molds are better for long-term, high-volume projects.

This doesn’t mean one is always better. It means it depends on your project. Here’s a comparison:

Aluminum vs. Steel Mold Comparison

For example, I worked with a client in North America who needed 5,000 units of a lighting fixture prototype. Using an aluminum mold, we delivered parts in just three weeks. If they had chosen steel, it would have taken twice as long and cost three times more.

When is aluminum the better choice?

• Your production run is under 10,000 units
• You want to test the market before committing
• Time-to-market is critical
• Budget is limited

When should you choose steel?

• Production run is over 100,000 units
• You need ultra-precise detailing
• The material is abrasive or operates at high temperature
• You need a mold that lasts for many years

Conclusion

Aluminum molds last between 5,000 to 100,000 cycles, making them ideal for prototypes and small runs. Steel is better for large-scale, long-term projects. Choose based on your goals.