Knowledge Center Center/Blog Friday, 22 January 2021 17:12:51 Friday, 22 January 2021 17:12:51 Cast Aluminum with Thin Walls /en-sg/resources/knowledge-center/cast-aluminum-with-thin-walls {9B9F3F60-6819-4043-86E5-13C90D9EF148} <p>When you think of&nbsp;aluminum die casting, do you think of big, bulky components with thick wall sections? Don’t worry, we did too! What if I told you that we can now cast aluminum parts that are almost as lightweight as their&nbsp;magnesium&nbsp;counterparts and offer more benefits like higher tensile strength and additional finishing options? In the past, design engineers have shied away from aluminum die casting because of the need for thicker wall sections (typically 1.5mm – 2.0mm) creating heavier parts.</p> <p>You might be asking yourself, “Why is it difficult to cast aluminum with thin walls?” Well, aluminum has a very high melting and freezing point so when molten metal is injected into a die, the aluminum starts cooling quickly and becomes solid. The window between the liquid state to the solid state is very narrow, which means the fill time needs to be less than 30 milliseconds for a thin-wall (0.5mm – 1.0mm) feature to be created. Our engineers do this with extremely precise process control—even small adjustments to more than a dozen variables can be the difference between success and failure. Good tooling design is equally important. Our tooling engineers need to find the perfect balance of the runner system and gating design, proper overflow placement and design, and targeted thermal management.</p> <p /> <p><b>Not interested in aluminum? Try our&nbsp;</b><a href="/knowledge-center/dynamic-process-metal-selector"><b>dynamic metal selector tool</b></a><b>&nbsp;to compare mechanical and physical properties of other alloys.</b></p> <h2>Evolution of The Thin-Walled Aluminum Technology</h2> <p>Historically, in order to cast aluminum with thin-wall sections, we would have used custom formulated high-fluidity alloys. However, our engineers recently developed a method to apply this technology to standard alloys. By using improved process control, state-of-the-art tool design, and machine enhancements, we fundamentally changed the die casting industry forever. &nbsp;</p> <h2>Benefits of Thin-Walled Aluminum Die Casting</h2> <p><br />One of the most important benefits of thin-walled aluminum die casting is that it creates lighter parts—with more surface finishing options than other die cast alloys. Creating a part with 0.5mm walls instead of 2mm offers a 75% reduction in weight, which is a big deal—especially when you’re trying to take weight out of an automobile component or a hand-held mobile device. Aluminum can also withstand the highest operating temperatures of all the die cast alloys. &nbsp;Moreover, cast aluminum is versatile, corrosion resistant; it retains high dimensional stability with thin walls, and can be used in almost any industry.</p> <p><strong>If you would like to learn more about our thin-walled aluminum die casting process,&nbsp;<a href="/discover-dynacast/contact">contact our team</a>&nbsp;today! We’d be happy to go over your next project with you and offer you a free quote.&nbsp;</strong></p> Thursday, 30 March 2017 12:00:00 Multi-Slide vs. Conventional Die Casting /en-sg/resources/knowledge-center/multi-slide-vs-conventional-die-casting {5FD71337-183C-4CEB-82DA-DBDCDC481ED2} <div class="content-block block-100" rel-id="5667"> <div class="inner"> <a name="block-5667"></a> <p>Our <a href="/specialty-die-casting/die-cast-process/multi-slide-die-casting">multi-slide die casting process</a> was originally invented in 1936. Since then, we have continued to improve our tools and machines. If you are using a conventional die casting process, it may be worth taking the time to understand how multi-slide works and how it could be a better fit for your project. If your part is less than 400g, multi-slide is usually the better option. Conventional die casting is great for larger parts that do not fit in <a href="/knowledge-center/blog/superior-quality-,-a-,-higher-density-metal-components">our A2</a> or <a href="/knowledge-center/blog/the-benefits-of-our-a3-machines">A3 machines</a>. The construction and operation of the tooling and the types of machines used to operate them are the major differences between conventional and multi-slide die casting.</p> <h2>Dynacast Tooling</h2> <p><a href="/specialty-die-casting">Conventional die casting</a> uses a two-part tool where multi-slide uses at least four perpendicular slides. Using more slides reduces variations and is more cost efficient when producing smaller parts with more complex geometries. Each die block has a cavity or a core on its face. When formed together, the molten metal is injected into the cavity and the part is cast.</p> <p><img border="0" src="-/media/229888C43E214E25A4EB09FCF88E4C0C.ashx" width="720" height="360" /></p> <p>Engineers and designers are always pushing the envelope with part designs wanting smaller, more complex parts that perform multiple functions; our multi-slide die casting process is the best option if your part is 400g or less. We can still create precise parts with our conventional die cast machines; however, the multi-slide tools are second to none when it comes to consistency and accuracy.</p> <p>Regardless of the process, we always focus on the design of our dies, putting in as many of the part’s features as needed to avoid secondary operations. Our goal is to achieve net shape the first time, every time. This careful planning eliminates the need for machining and reduces the overall part cost.</p> <p>To ensure longevity of our dies, our tool designers predict what part of the die may wear out and insert this as a separate piece of the tool so that we can easily replace one single part, rather than the whole tool when it wears out. This not only saves our customers a great deal of money, but it also ensure that we can get your project back up and running faster than if we needed to create a new die entirely.</p> <h2>Proprietary Die Cast Machines</h2> <p>Our unique multi-slide machines are only available within Dynacast. <a href="/knowledge-center/blog/how-we-upgrade-our-machines">Upgraded machines</a> are now equipped with thrusters that have a flexible crosshead adaptor system and a fast pneumatic injection system. We are capable of filling machines faster without heavy flash, which improves surface quality and decreases the porosity of parts. Our multi-slide machines make it possible for us to produce parts in mass quantities while still ensuring the best quality.</p> <p>Over time, machines age, parts wear, and technologies can become outdated. We build all of our machines in house, so our team of experts is constantly upgrading and making improvements to both our multi-slide and conventional die casting machines as well as the controllers that run them.</p> <h2>Multi-Slide Die Casting</h2> <p>Our multi-slide process is the best die casting option for small, complex parts. We can create net shape parts, typically without secondary operations—including internal and external threads. We are always updating and optimizing our tools and machines to provide our customers with the best parts possible. For more information on our proprietary multi-slide die casting process or to request a quote, <a href="/discover-dynacast/contact">contact one of our engineers</a> today.&nbsp;</p></div> </div> Friday, 12 August 2016 12:00:00 How Much Does a Die Cast Tool Cost? /en-sg/resources/knowledge-center/blog-how-much-does-a-die-cast-tool-cost {4A860848-F6ED-482C-8C9D-8C1B7F9EBBF9} <p>When searching for the answer to “How much does a die cast tool cost?” It is important to understand&nbsp;<i>why</i>&nbsp;a good die cast tool costs what it does. Be cautious of die cast manufacturers that offer tools at costs much lower than other die casting companies. Tools or molds, are not cheap and going the cheaper route can and will often lead to more troublesome problems down the road. When it comes to&nbsp;<a href="/en-sg/specialty-die-casting/die-cast-tooling-production">die cast tooling</a>, it is worth investing in the design and maintenance of the tool to ensure its longevity. &nbsp;</p> <h2>Superior Tool Design</h2> <p>Great tool design is critical to the overall success of your project. When you have a robust part, you want to make sure that your parts are consistent from the first shot all the way to the last. No matter how advanced your die cast machines are, if you cut costs for a cheaper tool, you run the risk of creating mediocre parts—which can add costs later on with unnecessary secondary operations—or worse complete project failure.</p> <p><img border="0" src="-/media/858704B36F55438FB62182EA825A426D.ashx" width="400" height="264" /></p> <h3>Runner Systems</h3> <p>At Dynacast, we pay more attention to the details of the design and aim to create a tool that won’t get us, or our clients into a bind during production. Not only is it important to work with experienced designers, but using predictive software, like MAGMA, can help to determine what the runner system should look like, how the part is gated, and where the overflows will be. We could just design one runner and vent system to save cost in engineering, but instead we design several runner systems and run multiple MAGMA integrations to select the best runner option along with the optimal overflow placement. If we can predict where porosity and failure will occur in the part, we can design a tool that will anticipate and correct it on the front end—rather than after the fact, which can be expensive.</p> <p><img border="0" src="-/media/F24EFBF2D43849948158EF0A1A13578B.ashx " width="447" height="250" /></p> <h3>Cooling Circuits</h3> <p>When you are creating a part using molten metal, you need to properly cool the part before removing it from the cavity. Removing the part too soon can change the shape of the part and compromise its structure. Some die casting companies just place a simple cooling circuit in the cavity block to save cost in design and tool manufacturing. At Dynacast, we regulate the temperature with very strategic cooling line placement and coverage. On larger more critical projects, additional time is invested in thermal analysis for cooling line optimization.</p> <h3>Tooling Inserts</h3> <p>Some manufacturers will just EDM the entire cavity to cut down on costs but our engineers incorporate smaller inserts into the tool design. When we design the tool with smaller shut offs it allows us to make adjustments during production. If a tool is eroding quickly, with every shot a critical feature could be changing. Instead of replacing the entire tool—which adds cost and slow production time—only part of the tool needs to be changed. We can predict which area of the tool will wear faster and make that a removable insert. Our customers receive better dimensional stability at a lower cost because we design our tools to last longer and provide better part-to-part consistency over time.&nbsp;</p> <h2>Proper Tool Maintenance</h2> <p>No matter how predictive your tool design is, over time metal on metal wears and it is important to make timely repairs. Our engineers can predict how long a tool can and should be used before performing maintenance so that downtime is limited. It is much easier and faster to perform maintenance on a tool than to create a new one due to failure. When your tool is not running, it is carefully cleaned and stored so it is ready to go at the start of your next project. Most of our facilities have an ultrasonic cleaning system in-house.</p> <h2>Prolonging the Tool Life</h2> <p>It is important to consider the life of the die when designing a tool. If you are making thousands of parts every year and you have to replace your die annually, how much money are you losing in downtime or tool costs? When you work with an experienced die casting manufacturer who can predict the longevity of the tool and design it to last longer, you will save tenfold over time. Proper tool design and maintenance will help to avoid weld repairs that often lead to weld sink and flash.</p> <h2>Leader in Die Cast Manufacturing</h2> <p>In over 80 years of business, we have built over 300,000 unique dies. Our engineers are constantly pushing the envelope with complex part designs and take pride in the quality of work that we provide. We aim to build dies that efficiently cope with high-volume production. With any die casting project, it is always a good idea to include a die casting engineer during the part design phase—it can translate into major cost savings in both design and production down the road. If you are interested in learning more about our in-house tooling or would like to receive a quote for your next project,&nbsp;<a href="/discover-dynacast/contact">contact our engineering team today</a>.</p> Thursday, 21 July 2016 12:00:00 Fiber Optics- The Importance of Reliability /en-sg/resources/knowledge-center/fiber-optics-the-importance-of-reliability {6BCD408F-49A5-4CF3-8F87-70A562AB2AB4} <div class="block-row" rel-rowtype="10"><div class="handle"></div><div class="row-delete"></div><div class="content-block block-100" rel-id="5190"> <div class="inner"> <a name="block-5190"></a> <p>It is no doubt that we are a hyper-connected society. With internet browsing and live streaming at our fingertips, consumers are constantly connected. We want everything in an instant and we want it fast. When it comes to high-speed internet, fiber optic broadband is becoming the gold standard in homes and businesses across the world. While Asia, Europe, and Latin American already have extensive fiber optic internet networks, the U.S. is expanding one city at a time. The best thing about fiber optics is that it can offer much faster speeds over much longer distances—if the components are working properly. When it comes to fiber optics and their metal components, reliability matters most.&nbsp;</p> <h2>The Right Metal For Your Fiber Optic Component</h2> <p>When dealing with die casting and fiber optics, it is important to find a die casting manufacturer that works with a variety of different alloys. From&nbsp;<a href="/en-sg/knowledge-center/material-information/die-cast-metals" target="_blank">aluminum to zinc,</a>&nbsp;different metals are fit for different jobs. Working with a die caster that has the ability to work with a variety of different metals ensures that you are creating a quality part from the right materials—not because it was the only option.</p> <p>Metal Injection Molding (MIM) is another option for fiber optics. The MIM process allows for more robust metals like stainless steel, as well as customizable alloys. Parts can be molded into more intricate shapes, with a wider range of sizes, tighter tolerances, and at high volume.</p> <p><b>If you are still looking for the right material for your fiber optic component, or you are interested in learning about other possible solutions, check out this&nbsp;</b><a href="/knowledge-center/dynamic-process-metal-selector" target="_blank"><b>metal selector tool</b></a><b>.</b></p></div> </div></div> <div class="block-row" rel-rowtype="60"><div class="handle"></div><div class="row-delete"></div><div class="content-block block-25 block-float-right" rel-id="5192"><div class="inner imageblock" style="line-height:0"> <a name="block-5192"></a> <img src="-/media/95059A9D4B2C49FAB05F2EC857F4CC80.ashx " class="image-block" alt="Dynacast part product photos. Die casting fiber optic transceivers." /><div class="caption"><p>Zinc and aluminum fiber optic die cast components created by Dynacast.</p></div></div></div><div class="content-block block-100 block-wrap-left" rel-id="5191"> <div class="inner"> <a name="block-5191"></a> <h2>Tooling and Design for Complex Parts</h2> <p>After choosing the right metal for your project, it is equally important to create exceptional designs and tools. When Dynacast is involved early in your design process our engineers can help you take advantage of our multi-slide technology. When you utilize our multi-slide technology, you can be more flexible with the directions of pull, which allows for more complex parts to be manufactured consistently without as many secondary operations—which reduces the cost per part.&nbsp;&nbsp;</p> <h2>Importance of Post-Cast Testing</h2> <p>Die casting—especially small precision fiber optic components—requires superb quality and consistency. Therefore, it is important to have controls in place to avoid dimensional, internal, and surface defects. For a thin walled and intricate component such as a fiber optic transceiver, you need to know that over time the part will not break or wear easily—specifically in harsh environmental conditions like high temperatures and high humidity. Partnering with a die casting manufacturer that will complete accelerated life testing to qualify your parts is crucial to the success of your project.</p> <p>Dynacast’s experience and resources provide our fiber optic customers a wide range of design, manufacturing, and value-added services like surface protection treatments. Our success with creating fiber optic components has helped us to develop working relationships with some of the industries leading suppliers. If you are looking to supply the growing fiber optics industry with quality components, it is important to work with a quality vendor.&nbsp;<a href="/discover-dynacast/contact" target="_blank">Contact one of our engineers today</a>&nbsp;to talk about your next project.</p></div> </div></div> Tuesday, 15 March 2016 12:00:00 What the Future Holds for the Automotive Industry /en-sg/resources/knowledge-center/blog-what-the-future-holds-for-the-automotive-indu {964142AF-8B0F-46AC-B4F7-03ECE8E64C54} <p>I remember being six years old driving with my dad, daydreaming about cars and what they may be like when I would be old enough to drive. I always was infatuated with cars and in my six-year-old brain, I was sure that by the time I was an adult, cars would have jet propulsion and wings that would let them fly everywhere to avoid the annoyance of traffic. I remember looking at my dad and asking him, “do you think cars will ever be able to drive themselves?” He looked back at me and said, “I don’t think in my lifetime, but if that happens, I would never trust that a self-driving car could be as safe as my driving.” Twenty years later, my question has been answered and my dad was wrong. Flying cars didn’t exactly happen the way I had imagined (though they&nbsp;<i>are&nbsp;</i>out there), but self -driving cars are going to be a very tangible reality for most of us within the next few years.</p> <p>A major milestone was recently reached through a partnership between Audi and Delphi. A car that they have named “Roadrunner” completed a 3,400 mile journey across the United States from San Francisco to the New York Auto Show in nine days without any significant human intervention. The car was able to accomplish this by using Delphi’s various active safety systems. The car was equipped with six long-range radars, four short-range radars, three vision-based cameras, six lidars, and numerous software algorithms analyzed all of the information coming in through these devices.</p> <p>The fact that a car was able to drive across the U.S. is an enormous accomplishment for both Audi and Delphi, but it’s also a milestone for the entire industry as it indicates a seismic shift in how consumers interact with automobiles. In a very short period of time, we may not be sitting behind the wheel of our cars, but in the back seat writing emails and sipping a latte while the car guides us through traffic.</p> <p>Delphi may have gotten the most publicity through their Audi partnership, but there are a number of other players who are also making a significant impact on the industry. Established companies like TRW, Bosch, Denso, and Valeo are joined by newcomers like Mobileye and Velodyne in creating various types of active safety systems. The active safety industry is projected to grow by 50% year over year for the next three years as auto manufacturers embrace this technology and as costs decline.</p> <p>As the technology becomes cheaper, cars will increasingly be available with multiple active safety systems; this means that driving will inevitably become safer. Some car manufacturers are aiming to have zero fatalities in any of their vehicles worldwide by the year 2020. They believe that with advances in technology, their cars will be intelligent enough to prevent most crashes themselves.</p> <p>Humans have had an obsessive enchantment with the automobile over the past century. Many people feel a genuine attachment to their vehicles and will argue that the technology controlling self-driving cars are not as capable as human beings at making quick decisions. It will quickly become evident that this argument does not hold truth, especially since as a society we are increasingly becoming engaged with the constant distractions coming through our wearable devices and smartphones. I predict that in the very near future – maybe within fifteen years – governments will deem people unfit to drive and a fleet of autonomous vehicles will ferry us wherever we need to go with a much lower rate of accidents. If you’ve seen the movie Minority Report, the self-driving cars in that movie seemed impossible at the time, but they may not be as far from reality as they were when the movie was released in 2002. A news story that validates the legitimacy of this certainty is that Mercedes recently announced that they plan to have a fully autonomous vehicle for sale by 2025.</p> <p>The automotive world remained a steady place to operate throughout the past seventy-or-so years. Mergers occurred, there were some major advancements in passive safety, and we saw brands like Pontiac and Oldsmobile disappear into obsolescence, but through it all, companies were still creating a product where a human sat on a seat and used a wheel to maneuver the vehicle. When I said that a seismic shift was coming, I meant it. This is going to be the first time that a machine will freely move humans around and we will begin interacting with cars more like we do with trains. Like it or not, you may question whether you are driving the next car your purchase or if it is driving you.</p> Tuesday, 02 June 2015 12:00:00 Surface Finishing Options Part One – Chromate and Chrome /en-sg/resources/knowledge-center/blog-surface-finishing-options-part-one {58823C57-DF45-42FD-9359-0870C902B708} <p>Is your part in need of a surface coating but you aren’t sure what would work best? My next four blog posts will feature some of the many different choices that Dynacast has to offer. We offer about thirty different coatings, from chrome to electroless nickel and many more. This post will focus on the chrome and chromate surface finishes. If you see a coating that you’d like but it isn’t listed on our site or mentioned in one of my blogs, please reach out to us! We constantly add new surface coating options based on customers needs.</p> <h3>Chrome vs. Chromate</h3> <p>Before I get into the different coatings that are offered, I first want to touch on the differences between chrome and chromate. Chrome, which is short for chromium, is an element and is applied as an electroplated finish. The chrome that you are familiar with on cars or other materials has the shiny, metallic finish that it is most commonly associated. Chromate, on the other hand, is used to describe a corrosion resistant process that is classified as a conversion finish, rather than an additive finish. We have many different options for both of these finishes, which I will now go into more detail.</p> <h3>Chrome Plating</h3> <p>There are several types of chrome plating that we currently offer, two of which are bright and satin. Bright chrome is the mirror-like finish that you know from automobiles, toys, furniture, and more. It’s a finish that provides corrosion protection and good wear life, as well as a good appearance. Satin chrome has the same characteristics as polished chrome but has a duller finish. Both finishes are rack-plated, with layers of copper and nickel followed by a chrome layer.</p> <h3>Chromate with Zinc</h3> <p>The three types of surface finish for this section are clear, yellow, and black. Zinc surface coating is soft, decorative, and corrosion resistant. It protects the part by corroding before the base metal. For extra corrosion protection, chromates are applied over this zinc coating. Clear chromate with zinc is a slightly iridescent blue color when complete, while yellow and black both give the respective colors to the finished part.</p> <h3>Chromate without Zinc</h3> <p>We have two surface finish options that are chromate and do not contain zinc. These options are black chromate without zinc and yellow chromate without zinc. Black chromate without zinc is an inexpensive type of chromate. It’s typically used for parts that do not require a high amount of corrosion resistance. The coating goes directly onto a zinc die cast part. Yellow chromate parts are chemically milled and then chromated. This gives the part a dull finish. Both of these coating options are very thin and contribute no measureable thickness to the overall coating.</p> <h3>Additional Chromates</h3> <p>Olive drab chromate and trivalent chromate are two additional chromates that were not covered in the above sections. Olive drab chromate has a dark green finish, and can pass 150 hours to white corrosion.</p> <p>Trivalent chromate has similar characteristics to a typical chromate, but does not contain hexavalent chromium. This eliminates the issue of chrome reduction in waste treatment, and is not harmful to humans or the environment. The color is bright blue and it exceeds the requirements of automotive specifications.&nbsp;</p> <p><i>What questions do you have regarding chrome? Chromate? Is there a particular color you’d like to see that isn’t currently outlined? Let me know, I’d love to hear your thoughts.</i></p> Tuesday, 31 March 2015 12:00:00 How Culture Drives Growth and Profit /en-sg/resources/knowledge-center/how-culture-drives-growth-and-profit {F551554E-A205-479B-9C6B-376F5C4FC0E4} <p>My <a href="/en-sg/knowledge-center/blog/the-necessity-of-being-agile">previous blog post</a> focused on three key areas that are critical to the success and growth of manufacturing: our people, our customers, and our plants. For this post, I want to expand on one of those key areas, our people. Dynacast’s employees are the reason we are as profitable and successful as we are. Specifically, the culture we have been able to cultivate over the years has been a determining factor in our success. Our culture is rooted in trust, but also in the ability to be agile and adapt to changes. With 5,500 employees spread across 16 countries, it is hard to ensure that the culture is integrated fully, but it’s something that Dynacast works hard to achieve. How do we do it? It starts before someone is even considered for an open position.</p> <p>Before the hiring process begins, we make sure there is a complete understanding of what the role is, what the person will be responsible for, and what type of person best fits the role. This is not just about degrees or experience – we also look at the compatibility someone will have when working with their peers and also what motivates them. We strive to hire people who have a passion for what they do and have a vested interest in the company. The hiring process is one of many factors that help us maintain a very low turnover rate and it also gives us the opportunity to hire the correct fit not only for the position but also for the culture of the company. <br /> <br /> What else do we do to ensure we have a strong culture? We encourage our employees to find their passion. If they were hired in a plant, but then become passionate about sales, we listen to them. We take their feedback and try to make a path for them to reach their goals. Dynacast understands that a person performs better when they are doing what that they are passionate about. It motivates the employee to perform at a higher level and learn as much as they can about the business.</p> <p>Dynacast has succession and progression plans to help employees achieve their goals. I am a great example of what can occur.&nbsp; I started with the company over 30 years ago and followed my passions, which eventually led to me becoming CEO of the company. We constantly encourage employees to learn about what interests them and to train with others. We also encourage them to travel to other plants in order to gain as much knowledge as possible. Dynacast is committed to building tomorrow’s leaders through developing our employees, and encouraging the sharing of ideas and innovation to instill the entrepreneurial spirit.</p> <p>Now that I’ve explained how our culture is built, I can discuss why it drives our growth and profits. Many leaders know that an engaged employee equals a higher performing employee, but do you know by how much? According to a recent <a href="">Gallup poll</a>, companies with high employee engagement outperformed their competitors by 147% in earnings per share. There is no doubt that employee engagement drives our growth and profits. Over the past years, we have consistently shown double-digit growth. We are on track to continue this growth rate, and within the next five years we have the potential to double in size. During this growth, making sure that our employees are engaged and our culture isn’t faltering will constantly be on our radar. Employee experience and a good culture ultimately drive the customer experience and create positive business results.</p> <p><i>How has your business grown as a result of your culture? Do you think that it relates directly to your profits? I’m interested to hear your perspective.&nbsp;</i></p> Tuesday, 24 March 2015 12:00:00 Dynacast's High Quality Tooling /en-sg/resources/knowledge-center/high-quality-die-cast-tooling- {EE35B611-26DB-435F-BAD8-C24C5E516204} <p>There are many die casting companies that make tools in order to manufacture a customer’s product. So why are Dynacast’s tools higher quality? As the Operations Manager for Dynacast’s Germantown tooling division, I’ve seen first hand why our tools are preferred over others in the business. Here are the three main reasons that our tooling is high in quality and capable of producing more precise components:</p> <p><b>1. Design for Manufacturing</b> <br /> The process for how we make our tools is one of the reasons they are higher quality. <a href="/en-sg/knowledge-center/multiple-design-solutions" target="_blank">Design for Manufacturing</a> (DFM) is an initial step that we take with our customers to make sure that any potential short falls of the tool are vetted and fixed before the tool is built. This could be as simple as moving a parting line, changing the draft, or modifying other features that not only improve the part for the customer but also increases the quality of the tool. In the design phase we can predict if there will be a place on the tool that will have significant wear. Once this is predicted we can create inserts for the tool that saves time and effort in maintenance.&nbsp; Because of these design modifications we can run our tools with minimal downtime.</p> <p><b>2. Tool Design</b> <br /> The materials that we use for our tooling is a critical piece of the tooling process. We use a specific steel type with an additional heat treatment that can withstand a high number of shots and maintain the integrity of the component being manufactured. The tool design also depends on the type of machine that is running the component. There are different steel types and hardness depending on the machine used. The cavities that we machine also makes our tools last longer than other manufacturers. Our designs create tools that last longer yet have gone through more shots than conventional tools. Our multi-slide technology typically comes with a lifetime warranty for the tool. This is not commonly done with other manufacturers, especially for conventional tooling applications; normally the customer will pay a small price per part for tooling replacements. We try to keep the replacement price low, if there is any, because the tool lasts longer.</p> <p><b>3. Tool Maker Experience</b><br /> I feel that the main differentiator between our tools and other manufacturers is our experience. In the tooling division of Dynacast there are about 25 toolmakers and 95% of them have been with the company for over 25 years. Their knowledge and years of experience makes an enormous difference in how long a tool will run. They are able to anticipate issues with the initial tooling design that others simply could not anticipate. Also, they’ve worked with thousands of clients so they have the knowledge of many different parts and design modification solutions for any issues that arise. &nbsp;</p> <p><i>What questions do you have about Dynacast’s tooling? Is there any additional information that you’d like to know? I’m interested to hear your thoughts.&nbsp;&nbsp;&nbsp;</i></p> Tuesday, 17 March 2015 12:00:00 The Benefits of Our A3 Machines /en-sg/resources/knowledge-center/the-benefits-of-our-a3-machines {8EE39F9A-91BB-4A7C-9A3D-6654D8CF408F} <p>As I mentioned in my previous blog on <a rel="noopener noreferrer" href="" target="_blank">A2 machines</a>, one of Dynacast&rsquo;s distinguishing factors are our unique machine capabilities. We have proprietary machines that use multi-slide technology and create fast cycle times and precision components. Below I&rsquo;ve given some additional details on another type of machine we use, the A3.</p> <h3>A3 SIS</h3> <p>The A3 SIS machine was created in 2010 and features a reinforced main plate with 28 tons of locking force. It can handle a die size up to 160 x 140 mm and a shot weight of up to 180 grams. Like the A2 SIS machines, the A3 SIS has the SIS injection system. This machine has a high CPM compared to conventional machines and also has the capability of more cavities for A2 parts. The A3 SIS machine is able to fill parts faster and produce no heavy flash. Because of this the part has improved surface quality and less porosity. The A3 SIS is able to handle more complex parts because it could have four slides plus more integrated ones.</p> <h3>A3 MAG SIS</h3> <p>Our A3 MAG SIS machine also features a reinforced main plate with 28 tons of locking force. The die size and shot weight are identical to the A3 SIS machine, but there are some differences in the machines. This machine has a two-chamber melting pot with 30 kW. It is suitable for small, high quality magnesium parts. There are no machining operations needed and it has a CE safety standard, as do all of our machines. Also, the machine has higher CPM, the ability to handle more complex parts, and manufacture parts with thinner walls and tighter tolerances when compared to conventional machines, especially cold chamber machines. &nbsp;</p> <p>Our A3 machines were created to enhance our capabilities and further help our customers with their precision component needs. In my next blog post, I&rsquo;ll discuss how we maintain and upgrade all of our machines to ensure the latest technology and safety measures are in place.</p> <p><em>What questions do you have regarding our A3 machines? I&rsquo;d love to hear from you! Please share your comments or questions below.</em></p> Wednesday, 11 March 2015 12:00:00 The Benefits of Our A2 Machines /en-sg/resources/knowledge-center/superior-quality-and-higher-density-metal-components {4769C2A9-3A45-4200-92DD-2FA9F5426399} <p>One of the factors that continues to distinguish Dynacast from our competitors are our unique four slide (multi-slide) machines. We have many different types of proprietary machines that allow customers a variety of options for die casting. In this blog post, I’d like to discuss the latest development of our A2 machines. These machines were created in 2008 specifically for Dynacast. It uses our multi-slide technology for faster cycle times and tighter tolerances.&nbsp;</p> <h3>A2 Thruster</h3> <p>Created in 2008, this A2 machine can handle components from 3.5 to 35 grams and 75x65 mm. It has four pneumatic movements and four hydraulic thrusters for a locking force of up to six tons. The machine is a low cost machine that’s used for higher quality demands. There are move cavities and a higher shot weight when compared to typical die cast machines. A2 Thrusters have a flexible crosshead adaptor system and a fast pneumatic injection system. The locking force is independent from air supply because it uses hydraulic thrusters.</p> <h3>A206 SIS</h3> <p>The A206 SIS machine was first created for Dynacast in 2011. Based on the A2 thruster machine, it is a low cost SIS machine used for higher quality demands. Like the A2 Thruster, the A206 SIS has four pneumatic movements and four hydraulic thrusters for up to six tons of locking force. The machine also takes up minimal floor space. One of the differences is that the A206 SIS has an SIS hydraulic injection system. This system is a two-phase injection that avoids heavy flashes and improves the surface and porosity of a part, therefore improving the part quality. There are constant process parameters that equate to high repeatability. A great feature of this machine is the ability to run data comparisons on current runs versus previous runs. This allows us to easily see if the parts are being manufactured the same throughout the entire process.</p> <h3>A210 SIS</h3> <p>The A210 SIS machine was created in 2009. This machine is typically positioned between our A2 and A3 machines and has ten tons of locking force. The A210 SIS is usable for all of the A2 die sizes that are available – which means up to 100 x 100 mm. The shot weight is up to 90 grams and it, like the A206 SIS, contains an SIS injection system. The A210 SIS machine fills parts faster without heavy flash and improves surface quality and decreases the porosity of parts. It has high CPM rates for A3 parts while being able to have more cavities for A2 parts than previous machines. There is also faster set-up time because it has a quick connector system for sliders.</p> <p>The A2 machines that we have available make it possible for us to produce parts in mass quantities while still ensuring the best quality. We are constantly upgrading and updating these machines to keep them running smoothly and to make sure they have the most up-to-date technology. Keep a look out for my blog on how we maintain our machines!</p> <p><i>What other questions do you have regarding A2 machines? Please share your comments and questions below.&nbsp;</i></p> Tuesday, 24 February 2015 12:00:00 Design Tips for Die Casting /en-sg/resources/knowledge-center/design-tips-for-die-casting {DAFB69B1-3B33-4079-B6F5-080B89F699E3} <div class="block-row" rel-rowtype="10"><div class="handle"></div><div class="row-delete"></div><div class="content-block block-100" rel-id="4522"><div class="inner imageblock"> <a name="block-4522"></a> <div class="flexslider" id="slide-1"><div class="flex-viewport" style="overflow: hidden; position: relative;"><ul class="slides" style="width: 1000%; transition-duration: 0s; transform: translate3d(-732px, 0px, 0px);"> <li class="clone" aria-hidden="true" style="width: 732px; float: left; display: block;"><img src="-/media/3989A275D8554C3D9C9A10C19F237323.ashx" alt="" draggable="false" /></li> <li style="width: 732px; float: left; display: block;" class="flex-active-slide"><img src="-/media/4C3A92F373F448F991588E444E9E5DFE.ashx " alt="" draggable="false" /></li> <li style="width: 732px; float: left; display: block;" class=""><img src="-/media/CD93E688A0B148AA9DC8B0E53DEE1CCB.ashx" alt="" draggable="false" /></li> </ul> </div> <ol class="flex-control-nav flex-control-paging"> <li><a class="flex-active">1</a></li> <li><a class="">2</a></li> <li><a class="">3</a></li> </ol> <ul class="flex-direction-nav"> <li><a class="flex-prev" href="#">Previous</a></li> <li><a class="flex-next" href="#">Next</a></li> </ul></div> </div></div></div> <div class="block-row" rel-rowtype="10"><div class="handle"></div><div class="row-delete"></div><div class="content-block block-100" rel-id="4581"> <div class="inner"> <a name="block-4581"></a> <p>At Dynacast we are often asked what tips we have that can improve a part design. I wanted to share with you some of the more common design tips that we recommend for die casting. Die casting can be done in various metals and the parts that are created differ widely. These tips listed below can help with the design of many parts. Also, remember to take into consideration the alloy that you would like to use, as well as any surface finishing that you’d like done after the part has been cast.</p> <ol> <li>The first tip that I’d like to share is regarding adding draft to a part. Adding draft means applying a slight taper on the internal and external walls of a part, normal to the parting line. This offsets the effects of shrinkage and makes it easier for the casting to be removed from the cavity. Adding draft makes it easier for a part to be cast.&nbsp; In general, recommended draft angles are in the range of ¼ degree to one degree per side depending on the alloy and process choices.&nbsp; Be sure to inform your Dynacast technical representative about critical areas where draft must be kept to a minimum.&nbsp; In many cases, near zero draft can be achieved in specific areas.&nbsp; Try to be mindful of draft when you are designing your component and apply liberal draft in non-critical areas from the beginning.</li> <li>Also, be sure to incorporate fillets and radii into your component design. Wherever possible, use generous fillets and radii, especially in non-critical areas. &nbsp;If you have an area where a fillet or radius is not possible or desirable, be sure to note it on your component drawing.&nbsp; Fillets and radii strengthen the component, improve metal flow and make the application of subsequent finishes easier.</li> <li>Ribs and bosses are used commonly in the design of a part in order to increase its strength. They should be blended with fillets and radii to eliminate sharp corners whenever possible. &nbsp;Since most ribs and bosses have non-critical side surfaces, be sure to apply draft accordingly.</li> <li>If the part that is being designed needs to be lightweight, one option commonly used is to design pockets in solid sections. This not only reduces the weight of the part but also decreases cycle time and reduces the cost. Again, be sure to apply draft and radii accordingly.</li> <li>When designing a die cast component, take into account everything the process has to offer.&nbsp; Consider adding features that have little-to-no added cost.&nbsp; For instance: logos, surfaces textures, integrated fasteners (rivets, studs), embossed part numbers, etc.&nbsp; The 4-slide die casting process can offer even more flexibility.&nbsp; Your Dynacast technical representative can help you with these options and more.</li> <li>Finally, there are tips I’d like to share for assisting with the flow of the metal into the cavity, to produce the final part. If a part has smooth corners and uniform sections, the metal can flow easier throughout the entire cavity, which means faster filling without producing metal flow turbulence. However, I know a uniform part is not always an option<i><u>.</u></i>&nbsp;In regards to flow, parts with long “windows” or slots can severely restrict metal flow, while round holes assist in the flow.</li> </ol> <p>I hope these tips have been useful to you. If you’d like to see more about these options, as well as additional options that I didn’t discuss, please see our&nbsp;<a href="/en-sg/knowledge-center/multiple-design-solutions/die-cast-design/part-improvement" target="_blank">part improvement page</a>&nbsp;on our site. It contains a wealth of knowledge on how to improve part design.</p> <p>Dynacast has a great design for manufacturing (DFM) service, which you can learn more about&nbsp;<a href="/en-sg/knowledge-center/multiple-design-solutions/die-cast-design" target="_blank">here</a>. This service allows Dynacast experts to look at your design and suggest tips on how to make the design easier to die cast and/or more cost effective.&nbsp;</p> <p><i>Are there other design tips that you’d like to learn more about? If so, what are they?&nbsp;</i></p></div> </div></div> Tuesday, 17 February 2015 12:00:00 Welcome to Our Improved Website /en-sg/resources/knowledge-center/welcome-to-our-improved-website {176FB4F4-FE45-4057-BCAE-CE9AB8B5CF5E} <p>For my first blog post, I’m excited to guide you through a few highlights of Dynacast’s improved website.</p> <p>At Dynacast, we know that visitors need to not only have an easy, quick way to find information, but also the ability to see Dynacast’s alloys, process offerings, and design expertise in a precise, detailed manner. On top of the added features I detail below, the site is completely rebranded, and is cleaner, more flexible, and easier to navigate.&nbsp;</p> <h3>The Knowledge Center</h3> <p>Dynacast is a leader in the small component manufacturing industry with over 80 years of experience, and this new section of our website showcases our expertise. The Knowledge Center is where you can find blogs, case studies, white papers, and a wealth of knowledge relating to manufacturing and die casting. You can dive deeper into our multiple processes and materials as well as the materials that we have available for your next component design.</p> <h3>Dynamic Process &amp; Metal Selector</h3> <p>One of the new features on our site is the dynamic process and metal selector. This selector tool allows you to easily compare different materials to see which one works best for your application. You can use the tabs to see the physical properties and the composition of each material. There is also a great feature at the bottom that allows you to either share your results by email, or contact one of our engineers about the results.</p> <h3>Our Blogs</h3> <p>The blog section of our website had a complete overhaul. So that you can learn from the experts from the Dynacast team, new blog content will be posted weekly. You can recommend topics that you are interested in learning more about, and your topics can be incorporated into future posts.</p> <h3>Case Studies</h3> <p>In order to make our case studies page easier for you, we added in a filter by topic option. We’ve also highlighted the newest case study and give you the ability to read a short description before reading the full document.</p> <h3>Heritage</h3> <p>Dynacast has over 80 years of history. In order to showcase this properly, we completely reworked the history page. It starts with the immigration of Otto Gries and continues into present day. It’s an easy to navigate, interactive timeline that showcases the evolution of Dynacast.</p> <h3>Locations</h3> <p>Our locations page features a streamlined, consistent view of all of the available manufacturing sites at Dynacast. You’ll notice that when you click into a specific location, you can easily see the address, phone number, machines available, and certifications.&nbsp;</p> <p>As you look through our new site,<i> let me know what you like and what you think could be improved.</i> We are constantly looking for ways to improve communications and make our site easier to use.</p> Wednesday, 04 February 2015 12:00:00 The Necessity of Being Agile /en-sg/resources/knowledge-center/blog-the-necessity-of-being-agile {1694785E-7138-4456-8B19-E7F66B6FA456} <p>I’ve been in the manufacturing industry for over 30 years, and throughout my career I’ve seen the growth from an industry focused on machines to an industry focused on innovation. Many people ask me, now that innovation is part of the process, what’s next? How do you keep a die casting company relevant and evolving? First, Dynacast has been in the business for over 80 years by staying ahead of the trends and listening to our customers’ needs. Currently in the manufacturing industry, there is a great need to be <b><i>agile</i></b>.</p> <p>I know that normally manufacturing and agility aren’t used in the same sentence, but it’s essential to see the relationship of the two. Being agile, <a href="" target="_blank">by definition</a>, is the ability to move not only quickly but also easily. If you think about it, doesn’t it fit into what us manufacturers do every day? Or at least what we all strive to be? In our industry, many goals are thrown out: faster production times, tighter tolerances, quicker deadlines, creating complex geometries with no errors, quick and effective prototyping, being safe, making a profit, being cost-effective to the customer, being competitive – the list could go on and on. For me, the bottom line is that being agile is of upmost importance. More specifically, being agile in three key areas is critical to the success and growth of manufacturing:</p> <ol> <li>Our people</li> <li>Our customers</li> <li>Our plants</li> </ol> <h3>Our People</h3> <p><b></b>Dynacast only hires the best of the best. How are we able to consistently hire top talent? And why do we have such low turnover? It really comes down to the agility of our people. We build a culture of trust and encourage our employees to find their passion. They are given the power to make decisions, speak up when they think of an idea, or present a way that something can be done better. A great case is our multi-slide metal injection molding machines (MIM). One of our employees thought, “Why can’t our multi-slide technology be used for the MIM process”? He began working on this concept, and soon after a new machine for MIM was born. If we weren’t agile, he would have never felt like he could bring his idea to the table. We quickly figured out the best way to help him in his concept, and made it as easy as possible for his vision to come to life. Dynacast not only supports, but we encourage this entrepreneurial spirit – allowing employees to be creative and think ahead. We also encourage movement within the company. If we have an employee who sees an opportunity he/she is interested in, we encourage them to get the necessary training and support they need so that their dreams become a reality. Dynacast realizes the importance of keeping our workforce engaged.&nbsp;</p> <h3>Our Customers</h3> <p>We are constantly changing and evolving with our customers. From mixing custom MIM powders to finding solutions for complex needs, we make sure that our customer’s success is a priority. A great example of this is the agility of our machines. Our multi-slide technology not only provides faster cycle times but they are also very portable in comparison to typical die cast tools, and are therefore able to be moved better. This means that we can quickly and easily move to locations based on what our customers need. Our sales team and our engineers partner with a customer from the beginning, to offer unique solutions and design ideas. Dynacast is a true partner, not just a manufacturer of one part for a product.</p> <h3>Our Plants</h3> <p>The final way Dynacast is agile is through our plants. We have simplified our plants making it quicker and easier to manufacture components. We have also moved locations, which has served multiple purposes, including being closer to our customers, lowering costs, and being closer to our suppliers. Each location is strategically and uniquely positioned to make the most business sense not only for us economically but also for our customers. Another great example of this is the opening of our tooling facility. This facility only makes tools. It was created out of the need to be able to make them easier and quicker. Because the sole focus is on tooling, they are able to create tools faster, which helps our plants meet deadlines and ensures the fastest turnarounds possible for components.&nbsp;</p> <p>By being agile, Dynacast has continued to grow and evolve. I am confident we will remain a leader in the manufacturing industry by continuing along this path&nbsp;</p> <p><i>Do you agree that being agile is important in the industry? Why or why not? I’d love to hear your thoughts.</i></p> Tuesday, 03 February 2015 12:00:00 Die Cast Material Spotlight: EZAC /en-sg/resources/knowledge-center/die-cast-material-spotlight-ezac {84EEB06F-6FC7-4C1B-A1C7-1253630C671F} <p>Eastern Alloys, Inc is constantly working on new alloys that result in better, more economical ways to die cast. By working closely with them, Dynacast offers alloys that many of its competitors do not. It ensures that our customers are receiving the best possible alloy for their components. Recently, <a href="">Eastern Alloys</a> introduced a new zinc alloy, EZAC<sup>TM</sup>.&nbsp; This may be the right fit for your die casting needs.</p> <h3>Zinc Alloys</h3> <p>Since the early 1900’s, zinc die casting has been available. Back then, it was known as the more lightweight, lower cost alloy in comparison to the other die casting alloys that were available – tin and lead. Over the past century, there has slowly been a progression in the zinc alloys. While zinc has always been known for its high strength, the addition of the Zamak family, and now EZAC, make hot chamber die casting zinc alloys even more suitable for multiple applications. Before EZAC, zinc was often overlooked for applications requiring high tensile strength and more specifically high temperature tensile strength. Additionally, most zinc alloys have a low creep resistance when compared with other materials. These areas of improvement were the focus when creating EZAC.&nbsp;</p> <h3>EZAC Benefits</h3> <p>The EZAC alloy has many benefits including superior creep resistance and higher yield strength and higher hardness when compared with other zinc alloys. EZAC performs approximately fourteen times longer than Zamak 2 and three times longer than ACuZinc5 in creep resistance tests at 140C and 31MPa, achieving 730 hours.</p> <p>In regards to yield strength, EZAC is comparable to ZA-27, which is the strongest cold chamber zinc die cast alloy.&nbsp; With a yield strength of 396 MPa – stronger than any other hot chamber zinc die cast alloy, EZAC achieves a 42% improvement over Zamak 2 and a 19% improvement over ACuZinc5. The hardness of EZAC also shows a 19% improvement over Zamak 2 and 11% improvement compared to ACuZinc5.</p> <p>While EZAC exhibits low elongation at approximately 1%, it maintains comparable Impact Strength with ACuZinc5 at 2.2ft-lbs.</p> <p>Compared with other high strength zinc alloys such as ACuZinc5 and ZA27, EZAC has shown excellent castability that does not result in accelerated wear on shot end components.</p> <p>If you are interested in learning more about the tests that were performed, as well as more about the EZAC alloy, please <a href=" BROCHURE.pdf">refer to this article</a>.&nbsp;</p> <p><i>What questions do you have about the alloy? Are there particular parts that you think would benefit from using EZAC?</i></p> Tuesday, 13 January 2015 12:00:00 Aluminum Spotlight /en-sg/resources/knowledge-center/aluminum-die-casting-spotlight {BF07159A-EE45-4AED-948D-E7381D69C6EB} <p>Aluminum is one of the most commonly used materials in die casting. It’s lightweight, strong, rigid, and can withstand high temperatures, which makes it common across many industries. Some other qualities of aluminum include:</p> <ul> <li>Good stiffness and strength to weight ratio</li> <li>Corrosion resistance</li> <li>Heat dissipating</li> <li>Fully recyclable</li> <li>Ideal for harsh environments</li> <li>Excellent EMI shielding properties</li> <li>Excellent thermal conductivity</li> <li>Good finishing characteristics</li> <li>Good machining characteristics</li> </ul> <p>At Dynacast, the aluminum alloys that are most commonly used in North America are A380, 383 and 413 with their equivalent Asian and European alloys being used in other regions. However, a number of other alloys are available depending on customer requirements and product design needs. Unlike primary aluminum alloys that have to be mined and extracted from ore, these secondary alloys are derived from primary aluminum scrap, which means they are more environmentally friendly. Dynacast has aluminum plants all over the world, which means your aluminum parts can be manufactured in a location that’s best for you.</p> <p>Below are two industry examples of how aluminum can be used:</p> <h3>Automotive</h3> <p>Die casting in aluminum significantly contributes to the weight saving requirements needed to improve fuel economy in vehicles. One of Dynacast’s strengths in the automobile industry is in electronic applications, where customers are looking for proven quality, part-to-part consistency, and high volume. Dynacast is a leading supplier in automotive parts such as airbag housings, retractor spools, shields for telematics equipment and housings for sensors.&nbsp;</p> <h3>Handheld Devices</h3> <p>Aluminum die cast shields and housings give EMI shielding, rigidity, and durability with minimal additional weight for handheld devices. This becomes an important quality when emission and interference suppression requirements are high.</p> <p><i>What are some parts you’ve die casted using aluminum? Did you feel like it was the correct metal for your parts?</i></p> Wednesday, 17 December 2014 12:00:00