Die Casting Mold Design and Development

Effective die casting can produce thousands of high-quality molded casts in a relatively short amount of time while utilizing a single mold. This highly economical and cost-effective approach to die casting mold design can produce casts with uniform quality and high degrees of accuracy. Die casting mold development provides premium quality, near “net shape” parts at a price point that is extremely cost-effective.

The machining process of die-cast parts must be considered well before any order for the tooling is released. A careful evaluation of machined requirements can lead to redesign for net shape die-casting or near-net shape with a reduced number of operations.

Contact us for more information regarding die casting mold design development or request a quote today.

1. Die Casting Injection Molding Services

1.1 Die Casting Mold Development

Our first class team of in-house engineers can oversee all aspects of tooling and the injection process. We can produce thousands of high-quality molded casts in a short amount of time.

3D Drawing for Die Casting

3D Rendition of casting converted from hog out configuration

Computer graphic of die casting mold

Aluminum alloy casting for aerospace industry

2. The Die Casting Mold Development Process

Die casting is an automated casting process in which liquid metal is pressed into a mold under extreme pressure at a high rate of speed. This casting process is highly suitable for mass production of components and is generally used with alloys that have a lower melting point. Since permanent metal molds are utilized for the die casting mold process, it is possible to produce large and complex components with low wall thicknesses.

2.1 Die Casting Molds

The molds that are utilized within the die casting mold design process are constructed from premium, heat-resistant steel grades. The molds are halved to form a cavity into which the liquid metal is pressed during the casting process. A die casting mold is so strong, over a million parts can generally be created with a single mold. However, the actual life of the mold will solely depend on the die casting materials that are used.

3. Advantages of Mold Development

Die casting utilizes non-ferrous metals (such as aluminum alloys or zinc alloys) to manufacture components. The chosen alloy for an application depends on budget, weight, and material properties. Other benefits associated with the use of die casting mold design, include:

  • High thermal conductivity
  • High electrical conductivity
  • Good processing properties
  • Very good EMI/ RFI isolation
  • High corrosion resistance
  • High strength and hardness

4. Mold Design Benefits

When it comes to high quality die casting mold development there are several influences that contribute to the overall success of the process. These factors include the following:

  • First Class Engineering, die-cast tools design in house. Manage and oversee all aspects of tooling by SKS.
  • Developing injection process parameters: gate size, location, feeding speed, fill time, injection pressure, press size.
  • Parting line, runner, overflows, venting, cooling.
  • Minimum and Maximum wall thickness.
  • Choice of the mold material and hardness based on mold forces calculation.
  • Superior or Premium Grade H13, Uddeholm Orvar or Dievar.
  • Flow simulation.
  • Draft, radii, filets.
  • Establishing machining stock.
  • Utilization of both domestic and overseas tooling suppliers.

5. Additional Considerations for Die Casting Mold Design

Some of the additional factors that should be considered before starting a die casting mold development project include the following:

  • Gate calculation, feeding speed and fill time.
    Press size, clamping forces calculation.
  • Shot sleeve choice and calculation.
  • Venting and overflows.
    Establishing cast and technological Datums
  • Establishing machining stock.

5. Contact us for Die Casting Mold Manufacturing

Contact us for more information regarding our die casting mold development processes, or request a quote for an in-depth price analysis today.

Thin Wall Die Casting

What Is Thin Wall Die Casting?

Aluminum thin wall die casting is a manufacturing process that generates parts that provide superior strength-to-weight ratios when compared to parts produced through other manufacturing methods. Aluminum die thin wall casting is also an efficient and economical process that can create a nearly unlimited amount of unique product shapes and sizes for industries throughout the world. Aluminum thin walled casts are also commonly used to supplement the aesthetic appeal of its surrounding part.

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