Our engineers work closely with you from start to finish

<p>Our team of skilled engineers will support you from the early stages of your project through to completion, applying design for manufacture principles and advanced technologies to ensure optimal results.</p>

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Engineering

Speak to an engineer

Dynacast’s expertise in Design for Manufacture (DFM) helps customers optimise wall thickness and incorporate features such as fillets and ribs to reduce weight, lower material costs, and improve strength and performance.

Collaboration through DFM

Engineers with an in-depth understanding of the die casting process can help ensure parts are not only functional but also manufacturable. Using advanced simulation tools such as MAGMA, parts achieve higher quality with fewer defects. 

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Improved part design

By helping to identify issues early in the design phase, engineers can eliminate costly design revisions and tooling modifications. This delivers overall cost savings for the project. 

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Minimise rework

Minimise rework, maximise savings

Early involvement of the engineering team can accelerate the design and tooling process by preventing design iterations and ensuring a smooth production start-up.

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Shorter lead times

Explore the advantages of Dynacast engineering

The DFM process considers part shape, material selection and casting processes.

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Shrinkage porosity occurs when casting metal contracts as it solidifies, leaving small pores. To combat porosity, parts are designed with uniform wall thickness and metal savers to reduce material weight and promote consistent solidification.

Shrinkage porosity

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DFM can incorporate fillets and radii to eliminate sharp corners, improving material flow and reducing stress concentrations. This design approach minimises cracking and extends tool life.

Fillets and radii

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Engineers optimise ejector pin bosses by strategically positioning and slightly indenting them to ensure smooth ejection from the casting. This approach prevents casting defects and improves overall part quality.

Ejector pin bosses

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DFM addresses draft by incorporating tapered edges into the design, ensuring parts can be easily removed from the tool without sticking. This improves die release and prevents defects.

Draft

Supporting the optimisation of your design for die casting

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<p>In today's business landscape, sustainability has moved beyond buzzword status; it is now a fundamental commitment across industries. Zinc, with its remarkable recycling rate ranging from 70% to an impressive 90%, has become a significant contributor to sustainable die casting practices. This translates into the recycling of 70 to 90 tons of zinc for every 100 tons produced, highlighting its pivotal role in promoting a circular economy. <strong>Zinc is an excellent metal for recycling because the quality of recycled zinc is the same as that of primary zinc, meaning it can be used to make the same products.</strong> This is because zinc is a pure metal and does not degrade when recycled. </p><h2>The sustainable cycle of zinc recycling for die casting</h2><p>The process of transforming zinc from discarded material into a valuable resource for die casting is carefully managed.</p><p>It begins with collecting zinc-containing materials such as galvanised steel, zinc alloys and zinc oxide. Once considered waste, these materials now form the foundation of sustainable die casting.</p><p>To achieve the purity required for manufacturing, precise pre-treatment removes impurities such as lead, tin and nickel, ensuring that recycled zinc meets the highest standards for producing high-quality metal parts.</p><p>Pre-treated materials are transformed in the melting furnace, becoming molten zinc ready for forming metal parts.</p><p>With precision, molten zinc is shaped into ingots or moulds that meet specific die casting requirements. This demonstrates zinc's remarkable adaptability in <a href="/about-us/sustainability" target="_self">sustainable die casting</a>, including within recycling processes.</p><h2>Benefits of recycled zinc for manufacturing metal parts</h2><ul><li><strong>Quality and performance:</strong> Recycled zinc maintains the same high-quality standards as its primary counterpart. It preserves structural integrity, ensuring that metal parts manufactured through die casting deliver exceptional quality and performance.</li><li><strong>Cost efficiency:</strong> <a href="/metals/zinc" target="_self">Die casting with recycled zinc</a> benefits both the environment and your cost base. Reduced water consumption, lower energy costs and efficient zinc transportation all contribute to cost savings in die-cast metal part production.</li><li><strong>Customisability:</strong> Recycled zinc is highly versatile, enabling the production of metal parts tailored to your exact die casting specifications. This adaptability provides die casting manufacturers with a wide range of design possibilities.</li><li><strong>Sustainability:</strong> Choosing recycled zinc for your die casting process supports sustainability goals. It significantly reduces water use, curtails the need for additional mining and minimises the environmental footprint associated with die-cast metal parts.</li></ul>

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Discover the sustainability and performance benefits of recycled zinc in die-cast components, without sacrificing quality in manufacturing applications.

Benefits of recycled zinc in die casting

Recycled zinc is a key material in sustainable die casting, offering high-quality metal parts, cost efficiency and a reduced environmental footprint by retaining its quality through recycling and supporting a circular economy. 

Benefits of recycled zinc

<h2>Design engineering is changing, and it’s changing fast.</h2><p>Today’s die casting engineers are under considerable pressure to develop viable components quickly and more efficiently than ever before. And <a href="/additional-capabilities/engineering" target="_self">Design for Manufacturing (DFM)</a> discussions with your supplier are among the best practices engineers use to ensure proof of concept, <a href="/additional-capabilities/part-improvement" target="_self">part optimisation</a> and scalability.</p><p>Defining a successful plan and process for your part is just as important as the component itself. The design is crucial to the entire production process—and affects everything from material cost to time-to-market.</p><p>In this webinar, <strong>Design for Manufacturing: a critical step for successful production, </strong>Dynacast’s Senior Application Engineer, Max Gondek, discusses the benefits of working with an engineer early in the design phase of your die-cast part. He covers:</p><ul><li>How to reduce component weight</li><li>Why wall thickness increases cost</li><li>How to determine the best draft angle for your part</li><li>How to strengthen your casting with fillets and radii</li><li>And many more design tips!</li></ul><p>&nbsp;</p><p><strong>Complete the form to register for our free webinar.</strong></p>

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Discover how Design for Manufacturing (DFM) improves quality, lowers costs and increases efficiency across every stage of die casting production and launch.

DFM: key to successful die casting production

In this on-demand webinar, Dynacast’s Senior Application Engineer, Max Gondek, outlines essential Design for Manufacturing (DFM) strategies for optimising component design, reducing costs and improving production efficiency through early collaboration with engineers. 

DFM: a critical step for successful production

<p>Mould release is a critical step in the die casting process, ensuring that precision metal components are ejected from the die easily and without defects.</p><h2>What is mould release?</h2><p>Mould release, also known as die spray or die lubricant, is a liquid applied to the steel mould before each shot of molten metal. The liquid evaporates when it comes into contact with the hot steel, leaving behind a thin lubricating coating. This coating helps prevent the metal from sticking to the mould, making ejection easier.</p><h2>Why is mould release important?</h2><p>Mould release is important for several reasons:</p><ul><li>It prevents metal from sticking to the mould, which can cause defects in the finished part.</li><li>It helps metal flow more freely into the mould, resulting in a more accurate casting.</li><li>It reduces the force required to eject the part from the mould, which can extend mould life.</li><li>It can improve the cosmetic finish of the part.</li></ul><h2>Types of mould release</h2><p>Many different types of mould release are available, each with its own advantages and disadvantages. The best type of mould release for a particular application depends on the metal being cast, the complexity of the part and the desired finish.</p><ul><li>Water-based mould releases are the most common type. They are relatively inexpensive and easy to use. However, they can be less effective than other types of mould release at preventing porosity.</li><li>Oil-based mould releases are more effective at preventing porosity than water-based mould releases. However, they are more expensive and can be more difficult to use.</li><li>Silicone mould releases are a good choice for parts requiring a high-quality <a href="/additional-capabilities/surface-finishes-and-plating" target="_self">cosmetic finish</a>. They are also effective at preventing porosity. However, they can be more expensive than other types of mould release.</li></ul><h2>Mould release considerations</h2><p>Customers typically have two main concerns about mould release:</p><ul><li>Will mould release cause porosity?</li><li>Is mould release safe for medical and surgical applications?</li></ul><p>Porosity is a natural occurrence in the die casting process. However, the amount of porosity can be minimised by using the correct type and amount of mould release. Dynacast works with customers to select the mould release best suited to their specific application.</p><p><br />Mould release can be safe for medical and surgical applications if it is applied correctly and the part is properly cleaned after casting. Dynacast works with customers to ensure their mould release is safe for their specific application.</p><h3>Dynacast is an ISO 13485 certified die casting manufacturer</h3><p>Dynacast is an ISO 13485 certified die casting manufacturer. This means that we have met the highest standards for quality and safety in the <a href="/industries/medical" target="_self">medical device industry</a>. We use only the highest-quality mould releases that are safe for medical and surgical applications.</p><h3>Contact Dynacast today</h3><p>If you are looking for a die casting manufacturer that can provide the highest-quality parts, contact Dynacast today. We have over 50 years of experience in the die casting industry and a team of experts who can help you with every step of the process.</p><p><br />We will work with you to select the correct type of mould release for your application and ensure it is applied correctly. We will also work with you to ensure that your part is properly cleaned after casting.</p>

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Learn how mould release agents improve die casting by preventing adhesion, enhancing component quality and extending die life in Dynacast production operations.

Mould release in die casting | Dynacast

Explore the essential role of mould release in die casting, including its types, benefits and considerations for ensuring defect-free, high-quality metal components.

Using mould release during the die casting process

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Ensure quality by implementing key improvements from the start

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Engineering

Supporting the optimisation of your design for die casting

Shrinkage porosity

Fillets and radii

Ejector pin bosses

Draft

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