What is Die Casting? Design, Materials, Process

 

Die Casting is one of the most common metal manufacturing techniques used in the industry. The main charm is Its ability to produce parts at a rapid speed and relatively low cost. It has become the prime process for mass-producing high-quality metal parts.

So what is die cast?

  • It is a metal casting process that involves forcing molten metal inside a hollow cavity
  • Normally, only non-ferrous metals are suitable for casting
  • It is mainly preferred for medium to large volume production
  • It requires a high initial investment for tooling
  • The per part production cost is drastically reduced for long term production

The Die Casting Process

Die Cast is the Most Economical Mass Production Technique

Die casting is undeniably a popular choice for its obvious economic benefits over other processes. However, the economic advantage is hard to perceive in small scale projects. So, you may opt to diecast when you have a decent manufacturing demand.

There are countless diecast manufacturing companies spread all over the world. But, to get the most out of your money, it is crucial to partner with a qualified supplier. There are many tips and tricks in die-cast to reduce the overall production cost significantly. You should rely upon an experienced manufacturer to achieve these added benefits.

 

Sunrise Metal Has 10+ Year’s Experience in Die-Cast

Sunrise Metal is a proud diecast service provider in China with rich manufacturing expertise. We provide a complete solution for diecast operations. Moreover, we can help you with the design, prototyping, and finishing of your die casting products.

Die Casting Factory in Jiangsu Province

Effective Design for Manufacturing (DFM)

A good Design for Manufacturing can substantially decrease the production difficulty. It eventually reduces the lead time and cost of production. Our talented designers can make effective DFM enable efficient and cost-effective diecast operation.

Discussing and Reviewing the DFM

Dedicated Cast Facilities

Sunrise Metal has four factories in China. Among them, two of the facilities are entirely dedicated to handling casting operations. They have high-end die-cast equipment capable of handling any small to large casting project.

Superior Engineering Capability

Sunrise Metal has experienced professionals at your service, ready to answer your queries. You can discuss your project with our professionals to find the most viable solution. Moreover, we maintain an organized corporate structure and have separate teams dedicated to handling a specific task. Also, our R&D department is continually working to introduce innovative casting solutions for our clients.

Strict Quality Control

Our top-notch quality control standards aim towards maximum customer satisfaction. We have a dedicated team of quality control experts operating our advanced QA testing equipment. All of the parts produced by us go through intensive quality control.  So, we can maintain consistent quality for our casting products.

Inspecting a Part with Zeiss CMM

 

How Do You Design a Part for Diecast?

Die-cast part design usually refers to designing a mold for CNC machining, known as casting tooling. We develop the tooling design using a combination of CAD and CAM software. Here, CAD stands for Computer-Aided Design and CAM stands for Computer-Aided Manufacturing. Any casting design job starts with CAD modeling followed by CAM programming.

Sunrise Metal Designer Working on a Model

Below We have listed down the procedures involved in a typical casting product design.

  • We design a 3d CAD model of the product first. It is the representation of the final product. We design it keeping in mind some design considerations to reduce manufacturing difficulty.
  • Once the CAD model is ready, we prepare a DFM model for it. This phase focuses on designing the mold that is known as tooling. Our goal is to make the parts as easy to manufacture as possible. It can significantly reduce your production cost without sacrificing quality.
  • Then we create a toolpath for the final model using CAM software. The toolpaths are cutting patterns of the CNC machine. The CAM software converts the toolpaths into a machine-readable code called the G-code.
  • We run a mold flow simulation on the final model before proceeding with manufacturing. It helps us to identify any flaws in the design. So, the design can be improved if needed.

We welcome you to check out our Ultimate Die Casting Design Guide if you wish to know more about casting design.

What Materials Can be Die Cast?

It is used for manufacturing metal parts. It mainly deals with materials with a lower melting point. This makes it difficult to manufacture ferrous metals as they have a high melting temperature. However, it is not impossible to diecast ferrous metals. But there are better alternatives.

So, when we are talking about die-cast materials, we mainly refer to non-ferrous metals. The most commonly used non-ferrous metals include,

  • Aluminum
  • Zinc
  • Magnesium
  • Titanium
  • Copper
  • Brass, etc.

The materials mentioned above are almost always alloyed with other elements to make them more suitable for diecast. So, you will notice the word die casting alloy is used more often.

What are the Typical Diecast Processes?

There are various types of diecast processes in existence. Depending on the type of alloys, part size, geometry, each of them is suitable for a specific purpose only. Based on the type of material, diecast is mainly classified into two types.

  1. Hot Chamber Die Casting
  2. Cold Chamber Die Casting

Hot chamber die cast is adopted for casting metals with a low melting temperature. Whereas, Cold chamber diecast utilizes metals with a high melting point. These two processes have other variations as well to facilitate the process for different circumstances better. These are,

You should have a clear idea about the different die cast processes. It will help you determine the right process that can meet your quality requirements.

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