Die Casting vs. Injection Molding

Die Casting Vs. Injection Molding

When it comes to making your parts, you have a major decision to make. Should you make your parts using plastic injection molding or aluminum die casting? To help you decide, let’s look at the major advantages and disadvantages of each.

What Is Die Casting vs. Injection Molding?

The process of making a part is basically the same whether you are using die casting or injection molding. You create a die or mold in the form of the part you want to create. You then liquify the material and use extreme pressure to inject it into the die/mold. You then cool the die/mold with internal cooling lines and die spray on the die cavities. Finally, you open the die and remove the shot.

Although there are some variations in technique, the major difference between die casting and injection molding is that die casting uses some kind of metal, often an aluminum alloy, as the raw material, while injection molding uses plastic or polymers.

Which should you use? It should be apparent right away that if you use injection molding, you are going to end up with plastic parts and if you use die casting, you are going to end up with metal parts. If you know what sort of parts you want to end up with, you know right away which to use. But if you’re not sure which material is better for you and your company’s products, read on.

Benefits of Plastic Injection Molding

  • Production is quicker due to more flexibility in the molding process
  • Plastic Injection molds can accommodate different plastic or polymer materials
  • Fillers can be used in plastic molds to increase strength
  • Efficient process with very accurate finishes

Benefits of Aluminum Die Casting

  • Efficient process with a high degree of accuracy
  • No need for secondary operations
  • Complicated designs can be more easily cast
  • Produces higher-quality products with better tolerance that will last longer

Comparing the Molds

Many industries, from toy production to commercial aerospace production, depend on mold types to produce high-quality complex parts. Although injection molding and die casting have similar processes, significant differences exist between the molds used for each process type. 

Common differences between injection and die casting molds include:

  • Pressure: It’s necessary to use high injection pressure for die-casting production. The mold must be thick in order to stop cracking and deformation after the heat treatment phase.
  • Decomposition: It’s also necessary for die casting molds to decompose the higher pressure of material flow via the diversion cone since the gate type is different than the ones present on injection molds.
  • Exhaust: Exhausting gas from a die casting mold requires opening an exhaust slot and slag collection bag, while an injection mold simply needs ejector pins and a parting surface.
  • Quenching: The cavity in the die casting mold can reach temperatures above 700 degrees, so quenching isn’t an essential step. However, it’s an important step for the manufacturer to quench injection molds.
  • Treatment: Die casting tools is a highly corrosive process, so the surface typically requires treatment.

Aluminum Die Casting vs. Injection Molding

So why would you choose injection molding over die casting? If you are looking to produce a lot of parts very inexpensively, injection molding might be the way to go, as labor and material costs are fairly light, although it is important to keep in mind that the cost of the plastic injection molding machines themselves and any secondary equipment can be fairly expensive.

If accuracy in design is a high priority, or you are looking to make many complex parts in a short time frame, die casting is almost always the preferred option. Even if you are designing simpler parts, many people prefer the obvious feeling of durability and quality you get in a solid metal part over a plastic part.

Contact Premier Engineered Products for All of Your Aluminum Die Casting Needs

Once you have decided that aluminum die casting is the way to go for all your part manufacture needs, the next step is to contact Premier Engineered Products. We have been bringing great part designs to life for over 70 years with state-of-the-art equipment and highly trained engineers, making sure you get the best possible product manufactured in the most efficient way possible.

We are a family-owned, U.S.-based company that does all of our die casting in our cutting-edge die casting plant and have made high-quality parts for industries ranging from firearms to telecommunications to medical devices and more. Companies that know die casting call Premier Engineered Products.

At Premier Engineered Products, we are dedicated to helping you provide a better product to your customers by offering you great service and exemplary quality every time you place an order with us. We’re sure we can help you with your metal part manufacturing needs regardless of your industry. To find out how we can put our high-tech metalworking machines and expertise to work for you now, just contact us online today.

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