You've never heard of the die casting process before, have you? Discover how to effectively implement design tactics for maximum manufacturability in this section of the course. Optimizing the design of your component to take advantage of the die casting process is critical to realizing a return on your investment in cnc machining services. When designing your component, keep the manufacturing process in mind. This will ensure that your project is best suited for conventional die casting aluminum, multi-slide die casting, or injected metal assembly, among other options. To put it another way, engineers should approach each project with the goal of designing die casting aluminum to be as manufacturable as possible from the beginning of the process.

With the help of a fundamental methodology known as design for manufacturing (DFM), die cast parts are guaranteed to meet specifications while reducing the need for secondary operations. Given that these operations can account for as much as 80% of a component's cost in some cases, it is critical to minimize their impact during the component's design process. If you're involved in project management, DFM is much more than a theoretical concept. A cost-cutting and inefficiency-reduction strategy is implemented prior to the start of a project's manufacturing phase. Within the scope of this blog, we'll take you through three different approaches to designing your die cast component in order to maximize its return on investment.

When it comes to corrosion resistance and stability, thin wall aluminum is an excellent material choice, as demonstrated by the following example:Corrosion-resistant aluminum has excellent dimensional stability and hardness, and it is also relatively light in comparison to other metals. While attempting to reduce wall thickness, it is perhaps even more critical to ensure that the final product is uniform in appearance and performance. All of these factors will contribute to the production of consistently stable and repeatable castings that are well-suited for the manufacturing process in question.

Porosity can be caused by a variety of factors, including varying flow pressures and non-uniform solidification, which can be caused by variations in wall thickness. In order to produce a net-shape component with while maintaining consistent wall thickness, our engineers at Dynacast have a variety of tricks up their sleeves. Our engineers will core the thicker walls in order to achieve greater uniformity, while also incorporating ribs into the cores in order to ensure the structural integrity of the component. To avoid delays caused by redesigns, it is critical to consider the draft angles and tolerances that are achievable for the materials that will be used in your project when designing your component. Overall, for zinc, draft angles as small as 0.5o are achievable, whereas for aluminum, draft angles as large as 2o are achievable.

As an alternative, consider your design from a more comprehensive standpoint. When you know the non-critical dimensions of your component, you can design tolerance zones that are less stringent. It is not only possible to prolong the life of your tool by reducing the number of exact geometries that wear down, but it is also possible to plan the tolerance stack-up of your entire component by allowing for tolerance zones. Using this method, you can avoid machining and secondary operations whenever possible, allowing your design to do the majority of the work for you, and allowing you to extract the maximum benefit from your die casting process.