Ensure quality by implementing key improvements from the outset

<p>From the initial concept through to final production, ensuring that the right improvements are implemented in your die casting is crucial to creating a high-quality component.</p>

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Part improvement

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By refining parts early in the die casting process, Dynacast helps customers achieve superior product quality.

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Enhanced product quality

Proactive part improvement through DFM minimises the likelihood of defects, ensuring product reliability.

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Reduced risk of defects

Early part corrections streamline the production process, reducing lead times to bring products to market faster.

Blueprint of a metal part designed by a die casting engineer

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Accelerated time-to-market

Identifying and addressing potential issues upfront prevents costly rework and scrap.

Metal parts stacked into a shipping container

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Cost reduction

How do part improvements drive project success?

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Heat checking, a common die casting defect caused by thermal imbalances, results in cracking or surface damage. Our engineers optimise coolant flow, fine-tune process parameters and insulate the mould to dissipate heat effectively and mitigate this defect.

Heat checking

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Counteract gas porosity by optimising part and runner designs to enhance gas venting and prevent entrapment.

Gas porosity

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To combat soldering, where a thin metal layer forms on the die casting surface due to die erosion, we focus on eliminating thick sections and refining gate and runner systems to ensure even metal flow.

Soldering

Cracks can be prevented by reducing stress points and improving thermal management. Design for Manufacturing (DFM) techniques can significantly strengthen castings and enhance metal flow, reducing the likelihood of cracks.

Cracks

Dimensional issues can be addressed by adhering to drawing tolerances, monitoring critical process parameters (CPK), and considering thermal effects, draft and ejector pin adjustments.

Dimensional issues

Flash, the excess material escaping between mould halves, is prevented by adjusting machine tonnage, ensuring high tool quality and optimising process parameters.

Flash

Shrink porosity is reduced by optimising casting geometry and managing thermal conditions.

Shrink porosity

Flow marks, including cold flow and non-fillet defects, are streaks on the casting surface caused by molten metal flow. These are addressed by optimising part geometry, using flow simulation software for detailed analysis and implementing real-time process monitoring.

Flow marks

Our approach to defect-free production

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<h2>The robotics market opportunity</h2><p>Robotics is reaching a key moment in its evolution. Manufacturers are quickly moving from low-volume prototypes to high-volume production. Whether in collaborative robots (cobots), autonomous mobile robots (AMRs), quadrupeds, or humanoid systems, the goal is clear: achieve commercial success at scale.</p><p>However, scaling production introduces a critical constraint—cost. To compete in the market, robotics manufacturers must significantly reduce total production costs. Many early-stage designs rely heavily on CNC-machined components, which are precise but slow, expensive, and difficult to scale.</p><p>This creates a fundamental challenge: how do <a href="/resources/article/design-for-manufacturing-in-robotics" target="_self">robotics manufacturers maintain precision and performance</a> while transitioning to a cost-effective, repeatable production process?</p><h3>The challenge: from prototype to production</h3><p>Most robotic systems share a common architecture that includes joint nodes, structural links, actuator housings, drive modules, and heat sinks. These components are often assembled from multiple machined parts, brackets, and fasteners.</p><p>While effective for prototyping, this approach introduces several issues at scale:</p><ul><li>High production costs due to extensive machining</li><li>Increased assembly complexity and labour</li><li>Mechanical failure points at fasteners and joints</li><li>Weight inefficiencies that reduce battery life and payload capacity</li><li>Thermal management challenges in high-torque applications</li></ul><p>To move from prototype to production, manufacturers need a solution that simplifies design, reduces cost, and improves performance without sacrificing precision.</p><h3>Where die casting fits</h3><p><a href="/die-casting-technologies/multi-slide" target="_self">High-pressure die casting</a> offers a transformative path forward for robotics manufacturing. It is particularly well-suited for:</p><ul><li>Compact, high-load joint nodes</li><li>Bearing interface housings</li><li>Multi-axis joint structures</li><li>Actuator and gearbox housings</li><li>Wheel-drive modules and suspension nodes</li><li>Structural links such as hip, knee, and arm housings</li><li>And more.</li></ul><p>By enabling near-net-shape production of complex geometries, die casting replaces multi-part assemblies with single, integrated components.</p><h2>The Dynacast solution: engineering for performance and scale</h2><p>Dynacast helps robotics manufacturers overcome these challenges by delivering precision-engineered die cast components that support both performance and scalability.</p><ul><li><strong>Part consolidation</strong>: Die casting allows engineers to replace dozens of machined parts with a single structural casting. Integrated rib structures and mounting interfaces improve stiffness while consolidating multiple machined components into one rigid, reliable part. This reduces assembly time and eliminates common failure points.</li><li><strong>Weight reduction</strong>: Using low-density aluminium and magnesium alloys, Dynacast produces ultra-thin, high-strength walls that significantly reduce overall system weight, extending battery life and increasing payload capacity.</li><li><strong>Thermal management</strong>: Integrated cooling fins can be cast directly into motor and actuator housings, improving heat dissipation and enabling continuous high-torque operation without overheating.</li><li><strong>Mass scalability</strong>: Unlike CNC machining, Dynacast die casting supports high-speed, repeatable production at global scale. This enables robotics companies to meet growing demand while maintaining consistent quality and reducing per-unit costs.</li></ul><h2>Precision engineering advantages</h2><p>Dynacast’s high-pressure die casting process delivers:</p><ul><li>Exceptional strength, rigidity, and durability</li><li>Tight tolerances for precise bearing alignment and repeatability</li><li>Natural EMI/RFI shielding through metal enclosures</li><li>High-quality surface finishes suitable for critical applications</li></ul><p>These benefits are essential for robotics systems that demand precision, reliability, and long operational lifespans.</p><h3>Identifying the right fit</h3><p>Dynacast is best suited for robotics programmes that show:</p><ul><li><a href="/metals/aluminum" target="_self">Aluminium</a> or <a href="/metals/magnesium" target="_self">magnesium</a> structural housings</li><li>CNC-heavy joint or actuator assemblies</li><li>Multi-part designs with alignment challenges</li><li>Plans for volume ramp-up and commercialisation</li></ul><p>By contrast, applications limited to sheet metal enclosures or one-off prototypes may not fully benefit from die casting.</p><h3>Real-world conversion opportunities</h3>Key opportunities for design optimisation include:<ul><li><strong>Integrated joint actuator frames</strong>: Optimised rib structures and integrated interfaces improve stiffness-to-weight performance while consolidating complex assemblies into a single casting.</li><li><strong>Gripper and end effector bases</strong>: Integrated rib structures and mounting interfaces improve stiffness while reducing part count and assembly complexity.</li><li><strong>Structural components</strong>: Shoulder joints, quadruped foot bases, and arm link housings all benefit from increased durability and reduced weight.</li></ul><h3>Accelerating robotics innovation with Dynacast</h3><p>As robotics companies push towards mass adoption, the ability to reduce cost, improve performance, and scale production is critical. Dynacast combines <a href="/die-casting-technologies" target="_self">advanced die casting technology</a>, <a href="/additional-capabilities/engineering" target="_self">engineering expertise</a>, and <a href="/locations" target="_self">global manufacturing capabilities</a> to help customers meet these demands faster and more efficiently.</p><p>By rethinking how robotic components are designed and manufactured, Dynacast enables the next generation of robotics innovation.</p>

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Discover how die casting helps robotics manufacturers reduce costs, improve performance and scale production with precision-engineered components at volume.

Die casting for robotics manufacturing | Dynacast

Solving robotics manufacturing challenges with precision die casting

<p><a href="/additional-capabilities/engineering" target="_self">Design for manufacturing (DFM)</a> is a Dynacast core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations, which can often represent as much as 80% of the component cost. In other words, DFM enables design engineers to work smarter, not harder.</p><p>Modifying your part design to take advantage of the die casting process not only enables you to fully leverage the efficiencies of die casting, but can also better suit your business needs. Learn about the benefits of die casting and <a href="/additional-capabilities/part-improvement" target="_self">optimising your component</a> for manufacturability in our webinar, where we’ll cover:</p><p>Design for manufacturing core concepts</p><ul><li> Eliminating inefficiencies</li><li>Component optimisation for lower part costs</li><li>Extending tool life</li><li>The importance of early engineer involvement, and more!</li></ul><p><strong>Fill out the form to download our free on-demand webinar.</strong></p>

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Learn how to reduce component costs, improve manufacturability and optimise designs in our on-demand webinar on Design for Manufacturing (DFM) principles.

Removing cost at the design stage | Dynacast webinar

Discover how Design for Manufacturing (DFM) can streamline your design process, reduce component costs, and enhance tool longevity in our on-demand webinar, where we'll explore core DFM concepts, inefficiency elimination, and the benefits of early engineer involvement. 

Removing cost at the design stage

<h2>Design engineering is changing, and it is changing fast.</h2><p>Today’s die-casting engineers are under considerable pressure to deliver a viable component quickly and more efficiently than ever before. Discussions about <a href="/additional-capabilities/engineering" target="_self">Design for Manufacturing (DFM)</a> 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 costs 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>Reducing component weight</li><li>The cost impact of wall thickness</li><li>Selecting the best draft angle for your part</li><li>Strengthening your casting with fillets and radii</li><li>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, reduces costs and increases efficiency in die casting production through early engineering input.

DFM: key to successful die casting production

In this on-demand webinar, Dynacast’s Senior Application Engineer, Max Gondek, shares essential Design for Manufacturing (DFM) strategies to optimise component design, reduce costs and improve production efficiency through early collaboration with engineers. 

DFM: a critical step for successful production

Expand your knowledge of Dynacast part improvement

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