Are you a novice when it comes to the technique of die casting

  • Die casting is a complicated process; are you just starting out? In this section, you will learn how to effectively implement design tactics in order to achieve maximum manufacturability in your finished product.


    Make something that can be reproduced in large quantities.


    • If you want to see a return on your investment, it is imperative that you optimize the design of your component so that it can benefit from the die casting process

    • This is one of the most important things you can do to ensure that you get the most out of your investment

    • It is important to design your component with the production process in mind, regardless of whether your project will be executed using conventional die casting, multi-slide die casting, or injected metal assembly

    • This is because each of these processes has its own unique advantages and disadvantages that should be taken into consideration when designing your component

    • This will ensure the very best outcome that is possible

    • To put it another way, when approaching a new project, engineers should do so with the intention of designing it to be as manufacturable as possible to the greatest extent possible

    Design for manufacturing, also known as DFM, is a core methodology that, when applied to die cast parts, ensures that the parts perform according to the specification and reduces the need for secondary operations. DFM is also sometimes abbreviated as DFM. Given that these operations can frequently account for as much as 80 percent of the total cost of the component, it is essential to minimize them as much as possible during the design stage. Depending on the component, these operations can be broken down as follows:

    Utilizing design for manufacturing (DFM), which is not just an abstract concept, can help you cut costs and improve efficiency before you even begin production on your product. DFM stands for "design for manufacturing."This article will walk you through three distinct approaches to designing your die cast component so as to achieve the highest possible return on investment (ROI).

    Reduce the mass, as well as the thickness of the walls.

    When it comes to die casting, the material and the amount of time spent in the machine are two of the most important factors that determine cost. You can reduce the amount of either one that is required by making adjustments to your walls and ceilings, such as installing weight-saving pockets and making them thinner.

    It might look like the obvious solution is to reduce the amount of weight and wall thickness in the cross sections of the building. When something has a lower total weight, there must be a smaller quantity of it; when there is a smaller quantity, the price of the material must be reduced. It also means that the time needed for the substance to solidify is reduced, which leads to an increase in the number of shots that can be taken per minute. However, there are some businesses that, in order to achieve their financial goals, end up sacrificing the quality of their products or services.

    It is essential to make a concerted effort to reduce the weight of the part as well as the wall thickness while maintaining the strength of the part in order to ensure that the performance of the part is not compromised. When you are designing your component, you will need to take into consideration the mechanical and physical requirements of your project in order to select the alloy that is going to be the most appropriate and will function effectively with thin walls. In order to do this, you will need to take into consideration the mechanical and physical requirements of your project.

    For instance, if the component you're working on needs to be resistant to corrosion and stable, aluminum with a thin wall is a good choice because it offers both of those properties. In addition to being resistant to corrosion, aluminum keeps high levels of dimensional stability and hardness throughout its entire lifespan.

    Would you be interested in finding out which alloy is going to work the best for the project that you are working on? Utilize our interactive metal selector tool so that you can narrow down your choices based on the mechanical and physical properties you require!

    Always remember to keep the wall thickness at the same level.

    Even though we are making efforts to reduce the wall thickness, maintaining the wall's uniformity is of equal or possibly even greater importance. This will go a long way toward ensuring a casting that is stable and repeatable throughout the entirety of the manufacturing process, as well as one that is optimized for efficiency.

    Porosity can be caused by non-uniform solidification, which in turn can be caused by varying flow pressures, which in turn can be caused by walls with varying thicknesses. Porosity can also be caused by the presence of air bubbles. Die casting gives the engineers here at Dynacast the ability to create a component with a net shape while still keeping the wall thickness the same throughout. The engineers in our company have access to a wide variety of different methods.

    You can see in Figure 2 that the component on the left has several walls that are a significant amount thicker than the component's most narrow point. These walls are significantly thicker than the component's overall thickness. This can be seen in the section of the component that is the thinnest. If it were cast in this manner, the end product would be a component that was both more porous and fragile. Instead, our engineers are going to core the thicker walls in order to achieve more uniformity, and they are going to incorporate ribs in the cores in order to guarantee that the part will have sufficient strength.

    Consider both the draught angle and the tolerance zones before making any decisions.

    When you are designing your component, it is essential to keep in mind the achievable Draught angles and tolerances for the materials that will be used in your project. These should be taken into consideration as early as possible in the design process. Should this not be done, there is a possibility that the redesigned component will be delayed. Zinc can have a draught angle of up to 0.5 degrees, according to the majority of experts. The melting point of aluminum is between 0 and 2 degrees Celsius. Zinc has the ability to maintain exact tolerances between 0.001 and 0.002 inches, whereas aluminum has the ability to maintain tolerances between 0.002 and 0.004 inches. Zinc has the potential to have tolerances ranging from 0.001 to 0.002 inches.

    You will be in a better position to avoid building in costs that aren't necessary to the design if you keep the tolerable range as well as the achievable Draught angles in mind. Too frequently, companies will request precise tolerances and minimal draught angles, despite the fact that neither of these features is required to maximize the part's performance in the application for which it was designed. The results of their castings are always disappointing as a consequence of this.

    You should instead implement a strategy that is of a more holistic nature for your design and follow this advice. Find out which of the dimensions of your component are not absolutely necessary so that you can make tolerance zones that are more lenient. Making allowances for tolerance zones not only makes it easier to plan the tolerance stack-up of your entire component, but it also helps your tool last longer because there are fewer exact geometries that need to be worn down. This is because there are fewer exact tolerances that need to be worn down. This is due to the fact that there are fewer exact geometries that become worn down over time. Because of this, it will be much simpler for you to avoid machining and secondary operations wherever it is possible. This will enable you to make the most of the die casting process by putting your design to work for you, which will allow you to make the most of the die casting process.

    Work smarter, not harder

    You can take full advantage of the efficiencies offered by die casting if you modify the design of your component so that it can benefit from the process of die casting. This not only allows you to take full advantage of the efficiencies offered by die casting, but it may also better meet the requirements of your company.