When you think of outdoor decking, wood is probably the first material that comes to mind. But what if there were a better option? Something that will not deteriorate, warp, rot or require regular annual maintenance? The innovators at Calgary-based SigmaDek knew there had to be a better way and approached Dynacast to help them find it.
All the benefits, none of the drawbacks
When properly maintained, a deck extends your living space and adds value to any property. But as any deck owner knows, they can require considerable work. Year after year, timber decks demand regular maintenance, from resurfacing to varnishing. Without it, they can become unattractive and unsafe.
Until now, wood has always been the default material for decks. But not for much longer if SigmaDek has anything to do with it. We spoke with Brian Boettger, VP Product Development, to find out more.
A collaboration of experts
To achieve this ambition, Brian said they recognised that "we needed 'best-in-class' partners if we were to build the business to its full potential. We identified Dynacast as that partner and contacted them very early on."
The advantages of aluminium
To manufacture the precision components SigmaDek required, the company needed die casting expertise, which is why it turned to Dynacast. "Our expertise is not in die casting, so the opportunity to work with the team at Dynacast was invaluable. They had a complete understanding of the process and its various idiosyncrasies, helping to refine the design of each part," said Brian.
Meeting the challenge
To deliver parts that provided the required strength without increasing cost, Dynacast's engineers improved the design for manufacturability (DFM) of more than 30 unique die cast parts.
Changes included eliminating undercuts; adding draft angles to certain features; and adjusting wall thicknesses, structural ribs, gates, runners and overflows. By making the parts easier to die cast, the DFM modifications delivered a significant cost benefit. Savings resulted from less complex tooling, faster cycle times and fewer secondary machining operations.
Introducing a world first
The result? The world's first fully fabricated, non-timber decking system that meets all of SigmaDek's safety and maintenance goals.
Strong, sustainable and designed to enhance the appearance of any home, SigmaDek is the result of leading die casting and decking specialists working together to achieve a world first. In Brian Boettger's words, working with Dynacast meant "we are able to deliver a product to the end-user which we are confident meets or exceeds anything else in the marketplace."