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Die casting is an efficient, economical process that offers a wider range of shapes and components than any other manufacturing technique. Parts have a long service life and can be designed to complement the visual appeal of surrounding parts. Designers can gain many advantages and benefits by specifying die-cast parts.
High-speed production - Die casting offers more sophisticated shapes than many other mass production processes. Little machining is required, and thousands of identical castings can be produced before additional tools are needed.
Dimensional accuracy and stability - Die casting produces parts that are durable and dimensional stable while maintaining tight tolerances. They are also heat resistant.
Strength and weight - die castings are stronger than injection molded parts of the same size. Thin-walled castings are stronger and lighter than other casting methods. Also, because die castings are not composed of individual parts welded or held together, the strength depends on the alloy rather than the joining process.
Multiple finishing technologies - Die cast parts can produce smooth or textured surfaces and can be easily plated or finished with minimal surface treatment.
Simplified assembly - Die castings provide integral fastening elements such as bosses and studs. The holes can be cored and made to tap bit size, or external threads can be cast.
Die casting design
There are many sources of information on die casting design. These include textbooks, technical papers, literature, magazines, seminars, and courses organized by engineering societies, trade associations, and industry. Often, choosing a die caster to produce parts is an excellent source of information.
To get the most out of the die casting process, it is always a good idea to take advantage of the extensive experience of a custom die casting machine. New designs should be reviewed at an early stage of development. In this exchange of ideas, significant savings can be realized.
Under special conditions, the approximate size and weight limit data (Table 5) for die casting of different alloys may vary. If in doubt, ask your die caster. He is very familiar with his machines and equipment and can make suggestions (at the design stage) that may affect changes in tools and production, thereby reducing costs.
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