Lightweighting and part performance

The rapid growth of a new generation of automobiles is driving engineering innovation and technological advancement, while also creating challenges for automotive designers, engineers and their suppliers. Strategy no longer involves simply removing and replacing a few steel side panels with aluminium; lightweighting is now a whole-vehicle concept that improves not only fuel economy and emissions, but also performance and handling. At Dynacast, we understand that finding the right balance between design, cost and part performance can be challenging, and we offer design solutions to meet your needs.

Weight sensitivity through design

Our thin-wall aluminium casting capabilities are often the solution to many design engineers' challenges. We can cast aluminium parts that are nearly as lightweight as their magnesium counterparts, while offering higher tensile strength and additional finishing options. We achieve the right balance of overflow placement, runner system and gate design to provide customers with aluminium castings with walls as thin as 0.5mm.

Additionally, our engineers provide precise design for manufacturing techniques, such as removing a component's core to make the part lighter. With their die casting expertise, they can predict exactly where unnecessary material can be removed without compromising component strength. This technique is used repeatedly across any of our die casting alloys.

Alloy selection matters

While we excel at thin-wall aluminium, it is not the right alloy for every project. Fortunately, we offer a variety of alloys that can best suit your project, rather than requiring your project to meet the limitations of the alloy—or the die casting manufacturer that offers it. If you require excellent strength-to-weight ratios with outstanding EMI and RFI shielding, consider casting with magnesium. Ideal for electrical housings and connectors, magnesium has been a preferred alloy for automotive designers seeking to significantly reduce weight. Additionally, the accuracy we achieve when casting zinc makes it an excellent option for wear resistance. Its structural integrity makes it well suited for automotive safety and electrical components. 

Did you know that many of today's automotive design engineers are turning to aluminium when thermal management is required?

Engineering capability

Our best-in-class engineering team not only offers die casting expertise, but also has decades of experience designing for the automotive industry. We continue to help customers realise their design potential through rigorous design for manufacturing strategies. Whether using our state-of-the-art software to ensure accuracy in your component's design, tooling and manufacture, or our predictive engineering methodology to identify potential manufacturing issues, you can be assured that, by the time your part enters full-scale production, it is fully optimised for the die casting manufacturing process.

Stability through a global presence

No project is too large or too geographically dispersed for Dynacast. With 23 plants across 16 countries, our global presence aligns with yours. While many automotive manufacturers are affected by suppliers that close their facilities, our customers can be assured that our process stability extends far beyond casting accuracy. Our 80 years of manufacturing experience is supported by the customer-focused local service provided in each region. We understand that trust and relationships are essential for support, delivery and reliability, and we believe we can deliver on them—our leading automotive customers have been with us for over 25 years!  With Dynacast, you can launch programmes anywhere in the world seamlessly, with minimal risk and lower total costs.

Your automotive die cast manufacturer

Through years of building relationships with our automotive customers, we have found that working together on designs from the outset enables us to offer not only the best solutions to contemporary challenges, but also more effective pricing. By recommending the best casting solutions upfront, using a variety of alloy options and design techniques, we can create a higher-performing part that is lighter and more reliable.