When Does It Make Sense to Move to Die Casting?

Die casting is becoming a top option for parts production because it features significant advantages over many other methods. We’ve found it to be one of the more cost-effective solutions, especially when you’re working with complex parts, because it can achieve tight tolerances and build out unique shapes with less machining.

Dies can be made for parts that are simple or complex. As you go more complex, the cost increases, but that’s true for almost all production techniques. The advantage for die casting complex parts is that it can properly form your part in a single shot that forms within milliseconds of injection of the material.

The 5 S’s of Die Casting Advantages

While there are numerous benefits of die casting, these five tend to be the most influential. Each allows manufacturers to make a higher-quality product, often at a lower cost than other manufacturing methods:

  1. Selection. Die cast parts not only can be made in batches of multiple parts at once, but they can also be finished in a variety of ways. You’re able to add textures, smooth or coat each piece after making the casting.
  2. Simplicity. Fastening elements including bosses and studs can be designed into the part and formed during the casting process at no extra cost, and a unified design means final assembly is simple and kept in mind during every step.
    Heart monitoring machine knuckles produced through our die casting process
  3. Speed. Die casting is a high-speed production technique. You’re able to create parts with complex shapes and other requirements in quick succession with little to no machining required. You’ll also be able to create thousands of parts beforeyou need to do any additional tooling. Die casting tends to be a higher volume process that requires parts in the thousands, not hundreds.
  4. Stability. Heat tolerance is a major concern for many manufacturers. Die casting allows you to maintain that tolerance and achieve dimensional stability, all the while sticking to your tolerances.
  5. Strength. Plastic injection molding can’t hold a candle to die casting when it comes to strength. Die cast parts offer the same dimensional support but are stronger, even when wall castings are lighter or thinner. You’re creating one solid piece, ensuring internal strength and structure.

When to Choose Die Casting

Making the choice of moving your parts production to die casting really depends on your needs. If you’re working with complex parts and need a large volume, it’s typically a smart decision. If you are looking to create just a few pieces — or if you create a part only when it is ordered — you might not come out ahead because of the investment for the pattern and the tools in die casting.

One of the most important factors in adopting die casting is finding the right partner to work with for your project. Designs should optimize your material use and save on development time, but that requires a special touch. Different alloys will also have different die requirements, so having an uniformed partner could lead to poor quality parts.

Premier Engineered Products has been in the industry for 70 years, so we know a thing or two about proper molding and casting. We’re based in the U.S. and offer a variety of services that also cover CNC machining, metal finishing and assembly. Our expertise is aluminum casting, which fills the needs of most interested in die casting. Contact us today to learn more.

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