CCM Behind the Scenes: Diecast vs. Brass

Although many collectors know there is a difference in the alloys used to make brass and die-cast models the differences in the processes of making these two types of models is sometimes subtle and sometimes drastic.

When Classic Construction Models opened for business almost 25 years ago, its founder Bob Peterson, was an aficionado of vintage toys and models, including highly-detailed brass model locomotives. These replicas, outside of the running gear, were made of cast, etched and sheet formed brass. Its strength, malleability, ability to capture small details when cast and ease of joining allowed for the creation of models that approach being part-for-part recreations of an actual machine. These attributes were a key part of why our first model was made from brass.

Die casting has been used to make toys and miniatures for almost a hundred years. The basic process of forcing molten metal under pressure into a mold cavity made of hardened steel has remained relatively constant while the process of making the dies is the beneficiary of numerous high tech changes that have improved the ability to capture details. As the upfront cost of tooling is extremely expensive it is practical for only long production runs that allow the cost to be amortized over a large number of models.

When creating a model in either material, the driving factor is the level of detail in the drawings provided by the designer to the manufacturer. Simply stated, a model is never better than the drawings from which it is created.  With the advent of 3D drafting, it has become easier to share designs but again, poor drawings equal poor models.

From the drawings, the next step for every model is a hand sample, and it is this hand sample that guides the process of making molds for a die cast model or the components that will be cast, etched and formed for a brass model. For a brass model, making the parts is a laborious one-at-a-time process as they are literally made piece-by-piece. Given the qualities of brass, there are virtually no limitations as to design features and duplicating the original construction of a machine with sheet metal for sheet metal, castings for castings, and machined parts when appropriate.

For a die-cast model, the parts can be made faster in higher volume but because of the limitations of injection molding, with less detail. This means the designer must allow for “draft” so parts can be removed from a mold, as well as maintaining minimum thicknesses and part sizes. An example of where this is apparent is with cab walls and engine covers that will always be thick and bulky compared to a brass part. It’s also important to note that brass itself is far more expensive than the aluminum and zinc alloy used for die casting, so the cost per “finished pound” will always be higher.

Our first scale model, the Manitowoc 4100 Crawler Crane, was constructed of brass for a number of reasons – the most important being high detail and a small production run. This model was a game changer for construction model collectors as making it from brass allowed for details such as movable metal tracks – not “rubber bands” as found on other models - and a lattice boom that looked more realistic than anything previously offered. Given the information for its construction was transmitted virtually all by fax, it’s a testimony to the level of effort required to produce it.

We released our first die-cast construction model in 1995, and we have been pushing the envelope in this arena ever since. With features such as a finely detailed grill, accurate cab interior and individually-linked metal tracks it was declared “the best die-cast construction model ever” when it was introduced. As the industry has grown those features are now expected by collectors in every model they purchase. We are proud to be part of introducing more detail and accuracy that collectors now demand.

CCM will continue to make both brass and die-cast models as each has its own qualities and features for collectors. Just in case there was ever any doubt, we will also continue our quest to make the very best of both types.