Get to know die casting, a method of producing high volumes of detailed, geometrically complex metal parts. Learn what it is, the types of die casting process, what it’s used for, and its advantages and disadvantages.
For more information, please visit our website.
Die casting is a high-precision form of manufacturing metal parts. The processes used to die cast are similar to injection moulding, but they involve metal materials instead of plastic. Like injection moulding, die casting produces industrial grade parts from real production grade materials.
Example of Die Cast Parts Made at HLH Rapid
The die casting process is very versatile and is capable of producing parts with complex geometries and tight tolerances. Manufacturers like using die casting because it produces high volume, functional end use parts with complex shapes, using industry grade materials like magnesium, zinc alloy, and aluminum. It is also a highly repeatable process that allows 100,000+ identical parts to be made with ease.
High pressure die casting (HPDC) is a process that consists of four steps: mould preparation, filling, injection, and shake out.
There are two main types of die casting process: hot-chamber and cold-chamber die casting.
This method of die casting, also called gooseneck casting, is the most popular one in use today. It works by immersing a chamber of the injection mechanism in molten metal, thereby heating it up. Then, a metal feed system in the shape of a gooseneck directs the molten metal from the injection mechanism into the mould tool cavity. Hot chamber die casting works best for metals with lower melting points such as magnesium, tin, lead alloys.
In this die casting process, molten metal is ladled directly into the injection system. This means that the injection system doesn’t need to be immersed, hence the name “cold chamber.” Manufacturers use the cold chamber process to minimize machine corrosion. Cold chamber die casting works best for metals with high melting points such as aluminum, brass, and copper.
Whether the material is suitable for the die casting process depends on several factors. Firstly, it needs to be able to withstand the high temperatures and pressures of the die casting process. Other considerations include surface finish, material structural properties and other demands of your end-use application. Popular materials that are compatible with the process include non-ferrous, malleable metals like aluminum, magnesium, and zinc.
Link to Yuhui
Aluminium AlloysDie cast parts are most commonly made for use in automotive and decorative hardware applications. The process can be used to create a wide variety of parts and products, from engine components to toys. Die casting is also used in the production of many common household items, such as door-knobs and faucets.
Die casting is a complex process that when executed correctly, can deliver cost-effective, efficient and durable results. Therefore, it is strongly advisable to consult with a tooling and plastic injection moulding professional when undertaking such projects.
Perhaps because of the similar nomenclature, we have found that many customers wonder about the difference between die stamping services and die casting solutions. Below we discuss some of the advantages, disadvantages, and unique product applications for metal stamping vs. die casting.
Die stamping is a suitable manufacturing method for both ferrous and non-ferrous metals. In contrast, die casting is generally performed on non-ferrous materials, except in applications which use gray iron or cast iron.
For relatively simple metal parts, stamping can be more economical than die casting, the stamping dies are also less costly, however, with the increase of complexity, the cost of metal stamping will be raised because of the use of more additional components.
While die stamping is better for high-volume manufacturing of relatively simple parts, die casting is generally viewed as the more suitable process for producing large batches of highly complex components. Nevertheless, metal stamping services can also be utilized for complex parts with precise tolerances. This is especially true if you choose a metal stamping company that offers progressive stamping services backed by custom toolmaking solutions to build the best tool for your unique products.
In many cases, die casting is more environmentally-friendly than die stamping due to the amount of scrap metal and excess material used in the stamping process. However, through engineering and design improvements, an experienced metal stamping company can optimize your products to minimize both material usage and scrap creation. Furthermore, the advancement of modern industrial recycling methods continues to make metal stamping an increasingly sustainable process.
Since , Master Products has delivered world-class metal stamping solutions from our hometown facility in Cleveland, Ohio. We proudly serve commercial die stamping customers throughout the greater Midwest and beyond through our flexible and responsive contract manufacturing services.