I've got a question for my manufacturing friends out there. Lets say I'm building something that requires some aluminum (or similar) parts to be created about the same size as a small block chevy motor, but hollow with about an inch or so thick walls. The "box" could come in multiple parts per wall and fastened/welded together or whatever it takes to save on wasted material. If we're creating ~1000 of these boxes per year, should we use CNC/subtractive or some sort of casting? What are the pros and cons of each?
The answer really depends on the geometry of this “box” and whether it is functional or decorative. However, something the size you require would start with castings, probably sand (unless the geometry/mechanics requires lost wax). The reality is that anything requiring modern precision will probably require machining of those cast parts, but you won’t want to simply start off with a massive billet of metal.