Most often, die casting is used for producing components for various industries such as automotive, decorative hardware, and many more. The fact is die-cast parts can be seen almost anywhere, perhaps you are not aware that these things are made from die-cast metal. Some of the common finished products are gears and locks. Other examples include golf clubs, pumps, toys, hooks, door handles, power tool housing, as well as common engineering castings.

Die castings are often used in products that require the strength of a metal part such as pump handles and taps. Die-cast products are often used in compressor valves, engine fans, and camera housings. Die castings can be used as an interior enclosure and secure housing for zinc as well as electronic and computer parts. Additionally, die castings are an ideal option for electronic equipment applications since they have excellent EMI and ESD covering without any gaskets.

The die-cast metal industry is very flexible. In fact, castings have been used in various sectors for several years now. This is because it uses an economical, efficient process that allows various components and shapes to be done, unlike any other manufacturing method. Additionally, die-cast components can provide you with long service life. It even allows you to create a design that complements the visual appearance of the product. Product design engineers can take advantage of choosing die-cast components as part of their projects.

Since the die casting process is so flexible, using it on your component, project, decorative item, or finished product can give you a lot of benefits. The following are some of the many advantages:

Advantages Of Using Die Casting in Products

  • Compared to other manufacturing methods, it can create complicated shapes within closer tolerances.
  • Ensures that your components are stable and durable.
  • Increased rates of production with minimal or no machining needed at all.
  • Multiple functions can be combined to create a single, complicated part.
  • Compared to plastic injection moldings, die castings are much stronger.
  • Components can be generated with thinner walls which cannot be done with other casting methods.
  • Zinc castings can be quickly finished or plated with less surface preparation.
  • With mass production, you can create thousands of similar castings within certain tolerances.
  • Holes can be created to match any drill size.
  • Produces smoother surfaces compared to other types of casting including permanent or sand mold.
  • Allows external threads on parts to be created as part of the cast.
  • Zinc castings provide extreme corrosion resistance.
  • Integral fastening components like studs and bosses can be included so assembly costs can be reduced.

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What Are the Product Design Requirements?

There are some important factors to consider when designing an aluminum die-cast component. This includes its appearance, application, precision, performance, and obviously the cost. First of all, you have to consider what you want to achieve in your components and make sure that your requirements are proportionate to your budget. The following are some of the major things that you should think about when designing a component.

Application

When you design a product, one of its major considerations is its function. Aluminum die-cast components can serve as surface function as well as structural function. That is why it has become a more popular option than the others.

Due to modern technology, computers are becoming more powerful than ever. Consequently, the preciseness that can be attained by die casting has incredibly increased multiple times. Aside from their excellent structural importance, these aluminum die-cast components can also serve a great cosmetic function.

It is important that you should let the die caster know about the specific application of your component. They can help you in choosing the appropriate material and deciding the proper tolerances for the parameters depending on your requirements. Aside from this, there are also other important considerations such as conductivity, strength-to-weight ratio, corrosion resistance, and others.

Most often, clients end up paying for the strength and quality that exceeds their requirements. Hence, it is always a good idea that you know the application of your component.

Appearance

If you are creating an internal aluminum die casting component, then the appearance is not so significant. On the other hand, if you are producing an exterior casting component such as casing or housing, then the appearance will be relevant.

End users will likely appreciate aesthetic-looking products. Some clients do not mind the performance of the component, but they want to prioritize its appearance. Therefore, make sure that the external die-cast components must look good.

Hence, when designing your components, be sure to take into account the aesthetic aspects. The best thing that you can do is to choose in advance the type of surface finishing that you want to have. In addition, having a good finishing also means that your component will have additional protection against harsh weather conditions.

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Assembly Technique

The technique used for the assembly of aluminum die casting components can either be simple or complex depending on how complicated the component is. Keep in mind that conventional die casting equipment has some restrictions when it comes to the type of components that can be cast.

That is why casting parts with complex details were hard to achieve. Nevertheless, complicated components can be divided into proper segments. Then, after casting, these components will be joined together using an appropriate assembly technique. Some of the typical die-casting assembly methods are cored holes, fastening, injected metal assembly, welding, and others.

It is relevant that you should choose a particular assembly method for your die-cast components before you begin making your design. This is because the assembly technique that you choose will greatly affect your design. That is why it is significant that you select an appropriate assembly method that meets your requirement.

Budget

Aside from the design, you should also create a detailed cost budget for your specific component. Budget concerns can greatly influence any manufacturing business. Be sure that your design matches your proposed budget. An expert designer knows how to lessen the die casting cost without sacrificing the quality of your components.

To avoid overdesigning your components be sure to follow specific design parameters. This can also prevent any unnecessary expenses. For instance, with the addition of pockets, lighter parts can be designed without compromising their performance. This can help you in reducing material costs. Also, the reduction or elimination of undercuts and sharp corners can be minimized. At the same time, the difficulty of casting and tooling can be avoided.

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How To Design the Product Structure

There are a lot of challenges that come your way when you are designing an aluminum die-cast component. Regardless of how small the feature is, it can create a huge effect on the casting operation. That is why it is important that all the details should be designed properly based on the recommended guidelines.

Be sure to focus on the major features of your aluminum die casting design. During the product design, you will discover recommended precision for the most relevant features. Furthermore, you will know about the design considerations that you need to follow.

How To Choose the Material

Most often, the product design will differ based on the chosen material. There are some limitations that should be enforced for every type of alloy. The maximum strength and integrity of your aluminum die-cast components will require proper design and execution.

Depending on the content of alloying elements combined with aluminum, some important properties including the melting point, conductivity, strength, fluidity, and weight could vary. However, not all of them can be considered die-casting material. Some of the common aluminum alloys that can be used for the die casting process are A380, A413, and A383 (ADC12).

Aside from this, there are other aluminum alloys that can be used as well. It is important that you select the appropriate aluminum alloy depending on your requirements and budget.

What Is a Draft?

When designing aluminum die casting, one of the most important parameters is the draft. It refers to the inclination or tapering applied to the surfaces and cores of the component that are perpendicular to the separation line of the die. Sometimes it is also referred to as the draft angle.

An experienced designer will be able to provide a substantial draft wherever it’s required. If there is no sufficient draft, then it will be hard to remove the casting after it has solidified. It is even possible that the component will be damaged or much worse the die itself.

What Should You Consider When Designing a Draft?

When computing draft requirements for components, there are some things to consider. Generally, you can use a typical draft angle for several geometric features. Exceptions can be applied to the surfaces and internal walls. Usually, in this case, the draft is double that of the exterior walls.

SEI Castings produce aluminum die-cast products whether it is custom or standard. You can guarantee that we can provide you with high-quality products. If you want to know more about our products, then you may email us at sales@seimw.com.