Reduce Manufacturing Costs with the Right Die Casting Design

In the die casting process, molten metal is poured into a mould that is designed in the shape of end product. The molten metal is injected at very high pressure into the mould, so it takes up the shape of the mould. This die casting process is efficient and economical as it saves time, effort and also decreases wastage at the same time. Different metals such as zinc, tin, magnesium and aluminium as well as their alloys are used in the die casting process.

There are small steps that you can take to further reduce aluminium die casting process expenses. The entire production process can be made less costly by making subtle changes in the die casting design.

Reduce the Weight

When you reduce the volume of components required for die casting, you can proportionately decrease the weight and cost of die casting. If you pour more metal into the cast, then it will take more time to set and cool, which will eat up into your production time. So, you can go for slight alterations in the die casting design like designing pockets to make thinner cross sections or use ribs to strengthen the cast product. Care should be taken while designing the location of the pockets because the wrong positioning of the pockets can affect the product’s accuracy and strength.

Parting Lines and Ejector Pins

While designing the aluminium die castings, careful consideration should be given to the parting lines and ejector pins. The parting line should preferably be straight or flat, so removal becomes easy. Ejector pins are used to remove the cast products from the mould. If the pins are neatly designed, then they will not leave any marks on the cast when it is removed from the mould. So, you finished product will not have any unnecessary marks and scratches which could then require another finishing touch.

Radii and Fillets

While creating the Die Casting Design, care should be taken to avoid sharp corners. If there are less sharp corners in the Aluminium Die Castings, the finished product will be stronger and have a cleaner finish. Also, there should not be quick ups and downs in the cross section, which will lead to erratic flow of molten metal in the cast, and finally lead to an irregular finish.

There are lots of the other techniques that can be used while designing the cast. These techniques will not only ensure product strength, but also reduce production time and decrease manufacturing costs.

Aluminium Die Castings – An Economical Method for Metal Manufacturing

In the recent decades, there has been unprecedented improvement in various manufacturing fields, thanks to the development of the die casting technique. This method has made it easy for manufacturers to mass produce metal parts without any loss in quality or extra use of labour. The die casting is a pretty simple technique that involves melting compatible metals and pouring the molten metal into a mould. The cast or the mould is designed in the shape of the product for production. After the metal solidifies, the cast is broken and the metal part is removed. This metal manufacturing process has been adapted by various companies for manufacturing electrical equipment, automobile spare parts and other metal alloy-based products.

Any industry will adapt to a process only if it has any advantages for them. Aluminium die casting techniques have made the manufacturing process more efficient and economical. A huge benefit of using the die casting method for metal manufacturing is that one can produce thin-walled products without loss of strength or integrity. The cast can be designed in such a way that tiny additions are made to the casting, so it retains its strength even if the walls are thin. This process allows manufacturers to produce small parts without much hassle.

Aluminium die castings have high strength as well as a good finish, so manufacturers don’t have to spend extra time, effort and money on polishing the final product before sending it to the market. Plus, this technique allows manufacturers to produce very high volumes of products without using much manual labour. From melting the metal alloy to pouring it into the mould, most of the process can be automated.

The casts can be cut into complex shapes, and all the ribs, marks and other details can be engraved on to the inside of the cast. So, when the metal solidifies, all the markings and carvings are automatically embedded on the finished cast. You don’t have to spend extra manual labour in making those final finishing touches to the manufactured process. Plus, the scrap generated by this metal manufacturing can be recycled and used in the next manufacturing cycle. So, by using this method, you can greatly reduce wastage of metal.

As with all technologies, aluminium die casting too comes with certain disadvantages. You will have to invest more in the beginning for the cast and the tool. Plus, the lead time is a little long. Overall, if you consider all the pros and cons, we can safely say that this metal manufacturing process is indeed economical.