If your company needs metal parts and you are confused about whether die casting or metal stamping is appropriate for your needs, you came to the right place. Here at SEI Castings, we will be discussing the difference between die casting and metal stamping. Hopefully, after reading this article, you will have informed knowledge on which one will be appropriate for your metal part needs. If you want to know more information, keep reading below to find out.
Metal forming is the process of using metal whether in a liquid or solid state to create metal parts with various shapes, thicknesses, and sizes. Die casting and metal stamping are two of the metal forming processes that are commonly used by manufacturers to produce metal parts. The nature of the parts and their application often dictates whether to use die casting or metal stamping.
Die-casting is one of the most popular metal forming processes because it is efficient and it uses technology that helps create high-quality metal parts. Here are some of the processes involved in die casting.
- Clamping – This step is done by cleaning and lubricating the die, and then it will be clamped on both sides by using high pressure.
- Injection – This step is done by forcing the molten metal into the enclosed die.
- Cooling – This step is done by subjecting the liquefied metal to pressure until it cools and creates a new metal part.
- Ejection – This step is done by removing the metal part from the die.
- Trimming – This step is done by removing excess scrap metal produced during the manufacturing of die-cast products.
Ingots or billets of metal materials are used for the die casting process. Here are some of the industries that benefit from using the die casting method.
- Aerospace – Die-cast metal parts are created for small and large aircraft components.
- Automotive – Aluminum die-cast components are used to decrease the vehicle weight. Thin-walled housings are made from die-cast metal parts which will then be used to enclose electronic sensors.
- Cosmetic or decorative finishes – Die-cast components usually do not need further refining processes but can be enhanced if the metal parts are created as a cosmetic finish.
- Electronics – Die-cast metal parts are used as housings for various electronic components
- Furniture – Die-cast metal parts are used for furniture such as fasteners to fasten wood and other materials together.
- Home Appliances – Zinc die-cast metal parts are commonly used for different kitchen appliances like blenders, food processors, hand mixers, stand mixers, and toasters.
- Power Tools – Die-cast metal parts are used to create different power tools such as angle grinders, chainsaws, electric drills, and electric hammers
- Machinery – Die-cast metal parts are used to create different metal parts for various equipment used in different industries
- Toys – Diecast toys such as cars. It is created by using zinc alloy in a mold to create a specific metal shape.
What are the advantages and disadvantages of die-casting?
Die casting is the metal production process that is usually recommended for manufacturing high-volume metal parts with different geometric shapes and sizes. Some scrap metal is usually left after the process, but it is usually small enough that can be easily recycled. It is an efficient process of manufacturing metal parts with varying geometric shapes. Its resulting product is durable and has an excellent surface finish, so it will not require any post-production processes. It is often used to create thin-walled metal components. The die-cast tooling is efficient and economical because it is reusable and it is capable of creating small and large metal components. Die casting is an excellent choice for creating complex metal parts.
One of the disadvantages of die casting is that it requires the use of nonferrous metals only. It is prone to having inconsistent densities and can have issues with porosity due to the air bubbles that can be trapped in the die during the injection process of the liquefied metal. Die casting is not recommended for the low production of metal parts because it can be time-consuming and expensive in terms of creating the die. However, once the die has been created, you can easily reuse it to create more metal parts.
This process of metal forming is done by subjecting a sheet of metal to a hydraulic or mechanical press and it also uses a die, and high pressure that will be crucial for shaping the metal into the desired metal parts. The process also includes embossing, blanking, punching, flanging, and bending, depending on the needed parts, they are usually completed at once but some will require them to undergo different stages. Stamped metal parts are rarely completed after the assembly; they often undergo secondary machining and finishing processes. The secondary machining processes include deburring, grinding, riveting, and tapping. Secondary finishing processes are the following options such as black oxide, powder coating, and zinc plating.
In metal stamping, the metal is not required to be melted before creating new parts. It is a quick and efficient process. Here are some of the industries that benefit from using the metal stamping method.
- Aerospace – Metal stamping can provide aerospace manufacturers with high-quality precision high-value components and metal parts of various sizes that meet strict specifications and safety guidelines.
- Automotive – Metal stamping can produce metal parts with extreme precision and tight tolerances. Stamped metal parts that are used for automotive include metals such as aluminum, copper, and steel.
- Construction Equipment – Metal stamping can produce metal parts that can withstand extensive wear and tear and very high temperatures and also have corrosion and rust resistance.
- Electronics – Metal stamping can produce electronic components using low processing times and high levels of precision. Popular electronics such as augmented reality devices, smartphones, and smart home technology are known for using metal parts produced using the metal stamping process.
- Home appliances – Metal stamping can manufacture metal parts for home appliances such as fan blades, brackets, bearing retainers, terminals, fan motors, kitchen appliances, and other electrical devices.
- Lighting – Metal stamping can provide metal parts for industrial and commercial lighting applications for example lighting housings, brackets, and other components have different shapes and sizes with intricate features.
- Medical – Metal stamping can provide metal parts that are precise and have tight tolerances for medical instruments, devices, and equipment.
- Power Tools – Metal stamping can provide metal parts that are used in power tools, they are reliable, durable, and long-lasting.
- Telecommunications – Metal stamping can manufacture high-quality precision metal stamping components that are used in wired and wireless telecommunication devices like phones, cables, satellites, the internet, and other communication systems.
What are the advantages and disadvantages of metal stamping?
Metal stamping uses cheaper dies and lasts longer. It is usually required for creating a huge amount of metal parts. This process can use sheets of both ferrous and nonferrous metals. It can be used for high or low production of metal parts and can produce high precision and high-quality parts. Metal stamping also includes a high level of automation. The dies required in the metal stamping cost less and are easier to maintain.
The metal stamping process can produce complex metal parts but will require more tools. More tools are used for the process so it will be more expensive so it will not be an economical option if this is the case. The shape and thickness of the sheet metal are limited and offer little flexibility so if you need to create complex metal parts you will need more components and tools which therefore will increase the production costs.
Acquiring the necessary equipment for metal stamping will be an added investment for the company. During metal stamping, large quantities of scrap metal will be produced so it lowers its cost-effectiveness. Any changes that need to be done during the production process will be difficult because the die cannot be easily altered in the middle of the manufacturing process.
If you think that die casting is the better manufacturing process of metal parts for your company’s industrial applications, make sure to contact SEI Castings. We have the skills, knowledge, and experience and we use state-of-the-art technology and employ expert technicians to create high-quality standard and custom Aluminum and Zinc die-cast products in a short amount of time and at a reasonable price. If you want to know more about the die casting process and how SEI Castings can help with your die-cast product needs, please contact us today. If you want to request a quote for custom die-cast products, please click this link. If you have further questions or inquiries about our company or our products please fill up this contact form here.
If you are based in California or its nearby areas and you are searching for a company that offers standard and custom aluminum and zinc die-cast products, you must check out SEI Castings. We manufacture our die cast products using nonferrous metals like Aluminum and Zinc. We can also customize your orders. If you want to order from us, you can call us at 408-374-1031. We are located at 66 First Street #4 Gilroy, CA 95020. What are you waiting for? Contact us today! Choose a company like SEI Castings to provide you with standard and custom Zinc and Aluminum die-cast products.