Most industries are using die-cast metal components due to their tight tolerances and ability to create complicated shapes. It is more suitable for manufacturing durable, superior-strength metal components because of its fast production along with dimensional stability. The die-casting manufacturing process is well known for its cost-effectiveness and efficiency. However, it might be hard for you to determine the best metal material for your die-casting needs.
Different Types of Die Cast Metal Materials
Although different metal alloys can be used for die casting, some of the most popular choices are zinc, magnesium, and aluminum. Copper and brass can also be used for making die-casting components. Nevertheless, they are only ideal for less volume and customized products.
Every metal has its own advantages. However, most often, steel is compared to aluminum since both of these metals can resist corrosion and are extremely strong, which are perfect for metal part production. When doing a head-to-head comparison, steel-cast parts are much stronger compared to aluminum cast parts. Although there are aluminum alloys that are considered stronger than steel, for load-bearing situations, steel is greatly recommended.
Aluminum Die Casting
Aluminum is commonly used for manufacturing die-cast products due to its versatility. Aluminum die-casting is highly favored due to its corrosion-resistance properties. They are lightweight and can maintain accurate dimensions even for high-volume products.
Die-cast aluminum parts are solid, hard, and have strength-to-weight ratios, making them perfect for various applications that are performed in harsh environmental temperatures. At the same time, aluminum is cheaper than magnesium and even harder than magnesium. Aluminum die-cast products are great for high-temperature applications since they provide better strength compared to zinc or magnesium.
Magnesium Die Casting
Magnesium is another lightweight, high-strength metal that is commonly used as a replacement for aluminum cast parts since it has unique alloy properties and mechanical structure.
Magnesium is very light and has high-tensile strength. Compared to zinc or aluminum, magnesium is the lightest alloy for casting products. Sometimes referred to as a specialty alloy, it is less stable and softer than aluminum. Although it is lighter than steel, they have the same strength.
Zinc Die Casting
Zinc is the best option if you require a long-lasting metal material for manufacturing your die-casting products. It has a lower melting temperature, making it cost-effective especially for large productions. Zinc is appropriate for complicated castings that have complicated details.
It can withstand more impact compared to magnesium and aluminum. Zinc is perfect for die-cast components that require extreme strength, more than magnesium could provide.
Die Cast Metal Parts for Different Industries
Die casting offers high-quality metal components for a variety of industries. Aluminum diecast is usually used for producing electronic components, aircraft, and aerospace parts, as well as RV and vehicle components. Some examples of magnesium die-cast components are connectors, lab and medical equipment, and electrical housings. Some automotive parts, medical equipment, and tools are made from zinc diecast.
Which Die Cast Metal Should You Use?
The appropriate metal for your die-casting component will likely depend on factors such as budget, production volume, and intricateness of the design. A reputable manufacturer can provide you with high-quality metal die-cast components. They can help you in choosing the best die-cast material for your project.
Difference Between Die Casting and Injection Molding
When choosing the best manufacturing method for your components or applications, two of the most well-known options are injection molding and die casting. Both of these manufacturing processes have their own advantages and disadvantages.
Since both have some similarities, engineers and designers have a hard time figuring out which one is more appropriate for their components. To help you decide, it is important to learn about the differences and benefits of each manufacturing method.
What is Die Casting?
Die casting is a manufacturing method that uses mold cavities. To create a certain part or component, the molten metal will be filled into each cavity, and extreme pressure will be applied. Some of the most commonly used alloys for creating die-cast components are zinc, magnesium, and aluminum.
What are the Benefits of Die Casting?
Die casting can produce high-volume components, making it more efficient. Die casting also benefits uniform component parts, intricate geometries, dimensional stability, accuracy, and minimizing any secondary finishing or machinery.
What is Injection Molding?
Although this manufacturing process is quite similar to die casting, polymers and plastic are used rather than metal. Injection molding is a manufacturing process that commonly uses resins such as polyethylene, TPU, polypropylene, and ABS, as well as plastic materials.
What are the Benefits of Injection Molding?
Due to their flexibility, plastics are becoming more and more popular. Its advantages include its ability to use fillers, accurate finished components, and its capability to mix or use multiple materials.
How to Choose Between Die Casting and Injection Molding?
To figure out which manufacturing process is the best for your project, you have to consider your budget, time constraints, and component functionality. Die casting is best for complicated geometries that have short lead times. Components that are made of metal casting are more durable and long-lasting too.
On the other hand, the labor and material costs for injection molding are much cheaper. However, its costs could increase due to secondary machining requirements.
What are the Benefits of Die Casting for Medical Equipment?
With its capability of manufacturing high-volume products along with accuracy and precision, die casting provides uniformity and versatility, which are much needed for mass-producing medical equipment and instruments. Secondary operations are not required anymore due to their smooth surface finishes. That is why die casting is a favored manufacturing method for producing durable, high-strength, long-lasting medical equipment, and instruments.
Additional benefits of using die casting for medical equipment are uniformity of die-cast components, the capability of producing complicated geometries with strict tolerances and thinner walls, less machining required, dimensional stability, higher strength, and less assembly required.
What are the Metal Alloys Used for Die Casting Medical Equipment?
Die-cast medical equipment and instruments are usually made from aluminum or zinc. When creating die-cast medical components and parts, each metal alloy has its own benefits.
Aluminum is a favored option due to its corrosion resistance and lightweight properties. Aluminum die-casting products offer durability and high performance because of their EMI/RFI shielding properties and extreme strength-to-weight ratio which is ideal when producing a wide range of surgical instruments.
Zinc is best for creating die-cast medical instruments that require precise tolerances and thin walls. Zinc die-casting is suitable for medical parts that need dimensional stability since it offers quality surface finishes and high cycle rates.
The mechanical properties of zinc offer accuracy with intricate precision. Some examples of medical instruments made of zinc die-casting are wheelchairs, seat lifts, crutches, stethoscopes, and medical handles and panels.
It is important that medical die-cast parts and components must comply with safety regulations and FDA guidelines. That is why it is important that you should work with experienced and reputable die-casting manufacturers who know the regulations and compliance standards.
SEI Castings has extensive expertise and knowledge in manufacturing aluminum die-cast products. To request a quote, you can call us at (408) 374-1031.