Simplifying Die Cast Tooling

When it comes to manufacturing, we believe simple is always more effective and we do our best to avoid features which increase the cost of manufacturing and cycle time. This includes undercuts, bosses, and holes that need either subsequent machining or retractable core slides in the tool. They also tend to cause flash on exterior surfaces that lead to additional removal costs.

Die Cast Tool Redesign

Our engineering team is dedicated to creating the best tooling possible. So, even if you bring us a design that was previously cast elsewhere, we can optimize your design for die cast manufacturing to better serve your business needs. Examples of component tool redesign to eliminate core slides are shown here:

Movable cores are required (1), due to the outside features, whereas the part can be made without movable cores or core slides (2).

Eliminating Secondary Operations

Undercuts beneath bosses form features that prevent the part from being ejected by the die. By carefully redesigning the component, our engineers can eliminate subsequent machining or the addition of core slides required in a tool.

Design alternatives that eliminate an undercut formed by an interior boss are shown below.

In the original housing design (1), the bosses create undercuts that cannot be cast. An alternative design (2) relocates the bosses to the outside of the box, eliminating the undercuts. The original design (3) has the bosses cored by providing an opening through the bottom wall. The bosses are extended to the bottom wall of the enclosure (4), eliminating the undercut. But, without the additional coring (5), an excessive mass of metal will remain.

Die Cast Parting Lines

The parting line is the line left on the part where two die halves meet. The part may need to be trimmed along this line and the trim must be configured to it and maintained.

Our engineers can simplify the parting line configuration that will reduce the cost of manufacturing and maintaining the trim. In some cases a simplified parting line removes the need for a clean-up operation on external surfaces.

Dynacast works with customers all over the world including the NAFTA region to bring customers ideas to life with the highest quality precision engineered metal components on the planet. If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.

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Last updated 11.13.2019