Die casting is all about manufacturing precision parts fast. What shouldn’t be rushed, however, is the road to get there.
From protecting your ideas to ensuring the cast meets your needs entirely and maximises efficiency, investing time into the design stages is the key to success.
There are several pointers to keep in mind to achieve this. Read on to discover what these are, or talk to Lupton and Place now for expert advice.
5 top die casting design tips
The easiest way to ensure design efficiency is to follow good die casting guidelines from the start. Recommendations include:
1. Using consistent wall thickness
Die casting is the preferred manufacturing method for accurate, sharply defined metal parts. Essential to this precision is wall thickness, so it’s worth trying to minimise any variations in your design. Why? Because different metal depths mean different cooling rates.
A cast that has a uniform thickness is also preferable for the flow of metal and is likely to result in a superior cast.
2. Upsizing fillet radii
In simple terms, this is the rounding of interior corners within a cast. The bigger a fillet radius, the better the metal flow, improving cast quality.
Fillet radii also enhance a structure’s strength, as they redirect pressure and prevent excessive force from being concentrated on a sharp corner.
3. Including ribs and bosses
Ribs are used to increase the strength of a design without impacting on wall thickness. They also provide a path to aid the flow of molten metal, ensuring that all areas of the cast are filled properly.
4. Using pockets
For many businesses, a key driver for choosing die cast parts is their lightweight quality. This can be enhanced further by using strategically positioned air pockets.
When done correctly, this reduces weight and saves on metal costs – all without impacting on the overall integrity of the part.
5. Using draft
In the context of die casting, ‘draft’ implies adding a tapper to the internal and external walls of your part. The reason for doing this is to counteract shrinkage and make it easier to extract the die from the cavity.
Other considerations
By taking into account the above pointers you’ll be well on your way to designing an excellent component, but there are still additional factors that need consideration. These include:
· Alloy choice
Which metal do you intend to use? Aluminium is one of the most favoured options for die casting. Chosen for its lightweight quality, strength to weight ratio, and capability to withstand high temperatures.
However, it’s not the only option. Other frequently used metals include magnesium, zinc, and brass. Take a look at our blog ‘What are the most popular die casting metals?’ to find out more about the characteristics different metals can offer.
· Surface finishing
Ensuring a quality part requires detailed planning from beginning to end, which means it’s important to also give plenty of thought to the finished look.
Surface finishing can enhance both the appearance and functionality of a component and should be considered as part of your initial design. So, too, should details such as trademarks, logos, identification numbers, or manufacturing dates.
Design with the experts
The right design can help you to take full advantage of the die casting process, resulting in an enhanced end product and improving overall cost-efficiency.
To be confident in engineering an optimal design, you need to work with the best in the business – and that means the team here at Lupton and Place.
Leading the way in aluminium die casting, we bring all the latest techniques, equipment, and knowledge to the table. To take advantage of our skills and services, get in touch with the team today.