Reducing Manufacturing Lead Time

Design engineers take into account numerous factors throughout the development of a new project. Increasingly, two considerations stand out as particularly critical: achieving rapid turnaround times and accelerating time-to-market to stay ahead of the competition.

Engaging Dynacast engineers early in the design process is a key step in reducing lead time and gaining a competitive advantage. When our engineers are involved prior to finalising a print, they apply their design-for-manufacturing expertise to recommend modifications that enhance manufacturability. These improvements can significantly shorten lead times and, in many cases, lower component costs. While our customers possess deep knowledge of their components and assemblies, Dynacast brings decades of manufacturing experience that directly translates into the production of high-precision components.

Improve Manufacturability

Involving our engineering team early in the process can substantially reduce lead time by enabling design recommendations that improve manufacturability. By leveraging our manufacturing expertise, we ensure that designs are optimised for high-volume production through adjustments such as radius refinements or draft angle modifications. These improvements contribute to longer tool life, greater process repeatability, and reduced overall cost.

By collaborating with our team, you gain access to recommendations on alternative materials or processes that can enhance performance while reducing cost. Our tooling is designed to produce complex net-shape parts, enabling streamlined production by eliminating unnecessary steps such as machining or secondary operations. This approach not only simplifies manufacturing but also reduces the overall project cost.

Tool Design

Our team of toolmakers designs die cast tools that account for all critical features. Tooling can be optimised to accommodate tighter tolerances—for example, by avoiding the placement of a post that spans two die halves near the parting line. For components requiring cosmetic surfaces, we further refine tool design to eliminate gating in visible areas of the mould, ensuring both functionality and aesthetics are maintained. Approval Process Plans

The Dynacast team employs dual-track approval processes that leverage predictive analysis software to evaluate mould flow, optimise gating, and refine other critical parameters. Prototyping methods, including 3D printing, are used to validate measurements, ensure repeatability, and identify potential issues before the first tool trial. Through early involvement, we can optimise the manufacturing process so that the initial tool shot is nearly flawless, approvals proceed smoothly, and shipments are delivered on schedule.