<p>We offer die casting solutions that guarantee consistent quality and rapid deployment for business applications.</p>

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Dynacast delivers precision die castings with unmatched dimensional consistency, ensuring optimal performance and compatibility in complex enterprise systems.

Dimensional Accuracy

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The die casting process allows for efficient production, accelerating time-to-market.

Rapid Production

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Dynacast supports a wide range of metal materials, including alloys optimized for specific technological requirements such as conductivity, heat resistance, or lightweight properties.

Material Variety

In the fast-paced enterprise technology sector, rapid time-to-market is crucial, and Dynacast maintains consistent quality across high volumes of components.

High Production Rates 

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

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<p>SICK faced the challenge of creating a miniature, intricate sensor housing for their picoScan100 2D LiDAR sensor, requiring precision, durability, and near-perfect internal tolerances while navigating manufacturing complexities like limited draft angles and shot accuracy.</p>

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The Problem

<p>Dynacast provided collaborative design support, simulation-driven precision, and micro-casting to optimize the manufacturing of SICK's complex sensor housing, leveraging multi-slide die casting and offering end-to-end solutions from design to production.</p>

Precision in Partnership

<p>The collaboration resulted in seamless integration, with the sensor housing meeting all performance requirements and being delivered on time and within specifications. SICK expressed full satisfaction with Dynacast's execution and the flawless performance of the final product.</p><p></p><p><em>“Smooth implementation of the entire project without additional corrections” – SICK</em></p>

Flawless Execution

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<h1>Cast Aluminum with Thin Walls&nbsp;</h1><p>When you think of 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 magnesium 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><strong>Not interested in aluminum? Try our dynamic metal selector tool to compare mechanical and physical properties of other alloys.</strong></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.  </p><h2>Benefits of Thin-Walled Aluminum Die Casting</h2><p>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.  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, contact our team  today! We’d be happy to go over your next project with you and offer you a free quote. </strong></p>

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A process that allows for the creation of lightweight, strong aluminum parts with thin walls. 

Cast Aluminum with Thin Walls 

See the process to cast aluminum with thin walls, offering lighter and more versatile components. 

Cast Aluminum with Thin Walls

<h2>DFM for Aluminum Die Castings</h2><p></p><p>When you think of an outdoor deck, the first thing you think of is probably wood. But what if there’s a better option? Something that won’t degrade, 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.</p><h4>All the benefits, none of the drawbacks</h4><p>Properly maintained, a deck is an extension of your living space and an asset to any property. But as any deck owner knows: they can be a lot of work. Year-in, year-out, wooden decks demand regular maintenance—from resurfacing to varnishing. And if they don’t get it, they can become dangerous eyesores.</p><p>Of course, until now, wood has always been the default material used for decks. But not any longer if SigmaDek has anything to do with it. We spent some time with Brian Boettger, VP Product Development to find out more.</p><h4>A collaboration of experts</h4><p>In order to achieve this dream, Brian said they recognized “we needed ‘best in class’ partners if we were to build the business to its full potential. We identified Dynacast as that partner and reached out to them very early on.”</p><h3>The advantages of aluminum</h3><p>However, in order to manufacture the precision components SigmaDek required, they needed die casting expertise which is when they turned to Dynacast. “Our expertise is not in die cast, so having the opportunity to work with the team at Dynacast was invaluable. They had a complete understanding of the process and its various idiosyncrasies to help in the fine-tuning of the design of each part,” said Brian.</p><h3>Rising to the challenge</h3><p>In order to deliver parts which provided the strength needed but did not add to the price, Dynacast’s engineers improved the design for manufacturability (DFM) for more than 30 unique die cast parts.</p><p>Changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, gates, runners, and overflows. By making the parts easier to die cast, the DFM modifications produced a significant cost benefit. Savings came in the form of less complex tooling, faster cycle times, and fewer secondary machining operations.</p><h3>Introducing a world first</h3><p>The result? The world’s first fully fabricated, non-wood decking system which meets all SigmaDek’s safety and maintenance goals.</p><p>Strong, sustainable and designed to enhance the beauty of any home, SigmaDek is the result of the finest minds in die casting and decking working together to achieve a world first. In the words of Brian Boettger, working together 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.”</p>

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Explore how applying DFM to aluminum die castings ensures optimal performance and cost-effective results.

DFM for Aluminum Die Castings: Best Practices

DFM for Aluminum Die Castings

<h2><strong>The Challenge: Ensuring Strict Quality in Safety-Critical Die Cast Tool Transfers</strong></h2><p>A prominent manufacturer of air brake systems for heavy-duty trucks needed a reliable die casting partner to ensure the continuity and quality of their safety-critical components. With their production reliant on zinc die cast parts, they were faced with several critical tools needing to be transferred with zero disruption to their manufacturing schedule.</p><p>The company turned to Dynacast’s Peterborough facility, having previously experienced the team's technical reliability and industry expertise.</p><h2><strong>The Solution: Expertise, Communication, and Precision Engineering</strong></h2><p>Dynacast’s longstanding partnership with the customer laid the groundwork for a tooling transfer that was both technically sound and operationally seamless. The project’s success hinged on three pillars:</p><ol><li><strong>Open Communication and Dedicated Support</strong><br />Clear, proactive dialogue ensured alignment between both teams. Dynacast provided continuous technical support throughout the transition, enabling fast decision-making and issue resolution.</li><li><strong>Flawless Tooling Integration</strong><br />The transfer process was meticulously managed, with the tooling relocated directly to the Peterborough site for immediate integration into production.</li><li><strong>Relentless Focus on Quality</strong><br />With safety-critical parts in scope, Dynacast maintained stringent quality standards every step of the way—protecting both performance and customer trust.</li></ol><h2><strong>Engineering Highlights: Solving for the Unknown</strong></h2><p><strong>The absence of existing CAD files or tool documentation added complexity to the situation.</strong></p><p>The engineering team began with a <strong>comprehensive tool assessment</strong>, manually evaluating each tool to determine its condition, shot life, and overall suitability for continued use. With no existing CAD data or tool files, this hands-on inspection was critical to ensuring a reliable production setup.</p><p>Following the assessment, the team executed a <strong>direct facility transfer</strong>, transporting the tools straight to Dynacast’s Peterborough facility.</p><h2><strong>The Outcome: A Smooth Die Cast Tooling Transfer</strong></h2><p>The tooling transfer was completed successfully and fully integrated into production—without causing any disruption to the customer’s schedule. From the outset, Dynacast maintained the high-quality standards required for safety-critical components, ensuring reliable performance and consistency from day one.</p>

Discover how Dynacast ensured seamless production of safety-critical air brake components through transferring die cast tooling.

Tooling Transfer for Air Brake Parts | Dynacast Case Study

In this case study, you’ll learn how Dynacast helped a leading air brake system manufacturer seamlessly transfer critical die cast tooling—without disrupting production or compromising safety. You’ll see how clear communication, hands-on engineering, and a relentless focus on quality made it possible to maintain high performance and trust in a safety-critical environment.

How Dynacast Seamlessly Transferred Safety-Critical Tooling

Enhanced Performance for LiDAR Sensor Housings

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<h1>High Quality Die Cast Tooling</h1><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? The following outlines the three main reasons that Dynacast’s die cast tooling is higher in quality and capable of producing more precise metal components.</p><h2>Design for Manufacturing</h2><p>The process for how we make our tools is one of the reasons they are higher quality. Design for Manufacturing (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.  Because of these design modifications we can run our tools with minimal downtime.</p><h2>Die Cast Tool Design </h2><p>The materials used for Dynacast tooling are a critical aspect of the tooling process. A specific steel type with an additional heat treatment is employed to 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 running the component. Different steel types and hardness are chosen based on the machine used. The cavities machined in the tools also contribute to their longevity compared to other manufacturers. Dynacast's designs create tools that last longer yet endure more shots than conventional tools. The multi-slide technology typically comes with a lifetime warranty for the tool, which is uncommon among other manufacturers, especially for conventional tooling applications. Normally, customers pay a small price per part for tooling replacements. Dynacast strives to keep replacement costs low, if any, because the tools last longer.</p><h2>Tool Maker Experience</h2><p>The main differentiator between Dynacast tools and those of other manufacturers is 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 make 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 foresee. Additionally, they have worked with thousands of clients and have the knowledge to address a wide range of parts and design modification solutions for any issues that arise.</p><h2>Quality NAFTA Die Casting Company</h2><p>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. For those seeking a partnership to apply new tools and technologies or fully realize a design vision, Dynacast can help move businesses forward.&nbsp;Contact the team&nbsp;today to get the conversation started.</p>

Learn about high-quality die cast tooling, critical for producing durable, precise parts in a variety of industries and applications.

About Die Cast Tooling | High Quality Solutions

Dynacast's high-quality die cast tooling stands out due to its Design for Manufacturing (DFM) approach, superior tool materials and design, and the extensive experience of its toolmakers, ensuring precision, durability, and minimal downtime. 

High Quality Die Cast Tooling

<p>We understand that customers are under more pressure than ever to redesign components that keep up with rapidly changing technology and sustainability regulations. Many customers go about this by retrofitting past designs because it is the quickest and easiest way to production.</p><p>However, what customers fail to realize is even though their materials and designs may meet regulations and pass testing, there are more advanced and efficient options for manufacturing.</p><p>Register for this webinar to learn how die casting lends itself to solving some of the biggest challenges in manufacturing today. Also, we cover solutions for the following trends:</p><ul><li>Evolving technologies</li><li>Demand for skilled workers</li><li>Rising raw material price</li><li>Sustainability efforts</li><li>Changing regulations</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p>

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Explore manufacturing strategies and die casting solutions that address today’s evolving market demands.

Solving Market Challenges with Die Casting

Discover how die casting can help you navigate evolving technologies, sustainability efforts, rising costs, and other key manufacturing challenges. 

Manufacturing Solutions for Evolving Market Challenges

<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><h2><strong>Aluminum Alloys</strong></h2><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>Unlike conventional hot-chamber die casting, which utilizes a two-part tool, multi-slide employs four perpendicular slides in the tool, allowing for the creation of intricate and precise castings. This technology provides design freedom, enabling the production of complex geometries with unmatched accuracy.</p><h3><strong>Handheld Devices</strong></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></p>

Explore the benefits of aluminum die casting—lightweight, strong, and corrosion-resistant. Discover Dynacast's expertise in aluminum components.

Aluminum Die Casting Spotlight | Dynacast Article

Aluminum die has benefits and applications in various industries. Key applications include automotive and handheld devices.

Enterprise Technology

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

Dimensional Accuracy

Rapid Production

Material Variety

High Production Rates

Industry Leading Certifications

A Look At
Enterprise Technology Applications

REAL RESULTS

Enhanced Performance for LiDAR Sensor Housings

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Enterprise Technology

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Interested in starting your die casting journey?

Enterprise Technology

Enterprise Technology Leaders Choose Dynacast To Help Achieve Key Goals

Dimensional Accuracy

Rapid Production

Material Variety

High Production Rates

Industry Leading Certifications

A Look AtEnterprise Technology Applications

REAL RESULTS

Enhanced Performance for LiDAR Sensor Housings

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Enterprise Technology

Article

Webinar

Article

Global Reach, Local Expertise

Interested in starting your die casting journey?

A Look At
Enterprise Technology Applications