Manufacturing
Manufacturing

What is Die Casting?

Die casting is the process of injecting liquid metal under high pressure into a high precision mold. It is used to mass produce complex 3 dimensional structures with a detailed surface texture within a single manufacturing step without post treatment. Since the surface of the die is quickly cooled by the mold, the slowly cooling core creates a negative pressure within the cast metal, which makes it more rigid and increases its structural integrity.

How does Die Casting work?

 

 

  1. The mold is opened
  2. The mold is cleaned and in some cases surface treated or filled with oxygen
  3. The liquid metal alloy is poured into the injection piston
  4. The piston is closed and the metal is forced into the mold
  5. The metal fills the mold and starts to cool
  6. The mold opens and the casted solid die is removed

 

Advantages:

 

  • Complex structures within a single manufacturing step
  • Very precise
  • Very rigid and durable
  • Detailed surface
  • High volume
  • High yield rate

 

Disadvantages:

 

  • High tooling/mold costs
  • Welding and other post treatment can be problematic
  • Depending on process, reduced thermal conductivity

Comparison
Die casting
Extrusion
Stacked fin
Folded fin
Skived fin
Cost
medium to low
low
high
medium
low
Tooling Lead-Time
long
short
long
long
medium
Weight
medium
heavy
light
light
medium
Performance
high
limited
best
medium
limited