DIE CASTING

Design, engineering, manufacture

Die casting uses high pressure to force molten metal into a mould cavity. Die cast parts can be made to exacting tolerances and offer excellent unit cost efficiency at larger production run volumes. Typical casting alloys are aluminium, zinc and magnesium.

Typical use cases:

  • Non-ferrous metals
  • Medium to large quantity production runs
  • Small to medium size castings
 
Festo
BeumerGro
Dan doors
Arcasafe
Louis Nielsen
Iiamo
Dynello
FSHMachines
ICM
3shape
SAC
Ønskebørn
Vikingespillet Jels
 

DIE CASTING ADVANTAGES

Die casting can have significant advantages over other manufacturing processes, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. When you cast a part, you can create complex net shapes, including external threads and complex internal features with minimal draft angles—minimizing secondary operations. You can also combine multiple parts into a single part, eliminating assembly operations and lowering labor costs, with the added benefits of simplified stock control and greater component consistency.

Other benefits include:

  • Variable wall thicknesses
  • Tighter tolerances
  • Fewer steps from raw material to finished part
  • Fast production cycle times
  • Reduction in material scrap
  • Long tool life, especially for zinc and magnesium

DIE CASTING ALLOYS

Zinc, aluminum, and magnesium are the three main die casting alloys. They are normally non-ferrous and their mechanical properties vary greatly to fit almost every type of application a manufacturer may need. Not only can die cast alloys withstand high operating temperatures, but they are also fully recyclable. Die cast alloys also have:

  • Good corrosion resistance
  • High strength and hardness
  • High thermal conductivity
  • High electrical conductivity
  • Outstanding EMI/RFI shielding properties
  • Good finishing characteristics

Separately, each die cast alloy offers a variety of benefits that the other may not offer. That is one of the great things about die casting, you do not have to be limited when it comes to choosing the right metal.

DIE CAST PART EXAMPLES

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PRODUCT CASES WITH DIE CAST PARTS

DIE CASTING PROCESS

There isn’t one single process that can suit every project. Each project is different which is why Dynacast offers multiple solutions for all die casting needs. This ensures the right process is always used for the right application. At Dynacast, we offer three different types of die casting processes.

Hot-Chamber

Used for zinc, some magnesium alloys, and other low-melting, hot-chamber die casting is a great option for alloys that do not readily attack and erode metal pots, cylinders, and plungers.

Cold-Chamber


Better suited for metals with high melting points such as aluminum, during cold-chamber die casting, metal is liquefied and then ladled into a cold chamber where a hydraulically operated plunger pushes the metal into the die.

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or manufacturing die cast parts?

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Steve Haworth

Sales Manager

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