<p>Die casting technology is rapidly evolving to meet the stringent demands of the healthcare industry, enabling the production of more complex, precise, and patient-safe medical devices.</p>

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Dynacast provides precision die cast parts for medical devices that meet the needs of multiple users, varied environments, and patient variability.

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Our diverse range of metal materials and special coatings meet rigorous FDA/EMEA testing and validation standards.

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Our die casting technologies provide medical devices with essential durability and reliability while offering a balanced strength-to-weight ratio using materials like magnesium and aluminum.

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Dynacast offers design flexibility for medical devices that require intricate shapes and thin walls, ideal for instruments with complex geometries like forceps, clamps, housings and more.

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<h1>Get your free copy of Bulletproof Supply</h1><p>Don’t let manufacturing problems derail your project.</p><p>Our free ebook will help you spot some common supply chain risks so you can keep your projects on track.</p><p>Get your free copy of <em>Bulletproof Supply</em> by simply entering your details below.</p><p><strong>Download your free copy of Bulletproof Supply to learn about:</strong></p><ul><li>The three major areas of risk with outsourced manufacturing</li><li>Less-obvious ways manufacturing issues can affect your operations</li><li>The 7 risk mitigation angles required in today’s supply chain</li><li>The surprising way redundancy can eliminate points of failure</li></ul><p>And everything else you need to look out for. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“The impact of lack of preparedness for any of the risk factors – whether surrounding location, business practice, or robustness – can fall anywhere from barely noticed (if it doesn’t affect your project timeline) to white-knuckle investor calls—or worse.”</p><h3>Please fill out the form to access your copy of the white paper.</h3>

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<p>The best prototyping process for die casting depends on many factors. Most importantly, you have to consider the material restrictions of each process and the rigor of tests your prototype will be put through. If you’re looking for your prototype to mimic the mechanical and physical properties of your end component and withstand real-world testing, manufacturing your prototype with investment casting is the way to go.</p><p>Prototyping with investment casting entails either a short-run hard tooled wax pattern or a printed 3D wax, SLA, or PMMA pattern that is then run through the foundry just like any other production run.  </p><p><em>Do you need a refresher on the investment casting process? Check out this quick video from our sister company, Signicast.</em></p><p></p><p></p><iframe src="https://www.youtube.com/embed/y8xYLxgzNNE" width="560" height="315" title="Investment Casting Process | Signicast" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen=""></iframe><p></p><p>But what exactly makes investment casting a beneficial prototyping process for die casting components?</p><h2>Prototypes with exact mechanical and physical properties</h2><p>Unlike other processes, such as machining from solid or spin casting, investment cast prototypes have almost the exact same mechanical and physical properties to die cast components—like ultimate tensile strength, yield strength, and ductility. If you require your prototype to provide information on any of these characteristics, investment cast prototypes are extremely similar to die cast components.</p><p>Additionally, the investment casting process can hold tolerances similar to die casting when sophisticated design features are included in the casting. The die casting process still holds the ultimate crown with tolerances as exact as ± 0.02 mm., but Signicast’s as-cast investment casting process is capable of +/- three standard deviations when a single point location is repeatedly measured—typically +/- .003 to +/- .004 per inch. However, tolerance capability is largely influenced by part configuration.</p><h2>Wide alloy selection</h2><p>With investment cast prototypes, you’re not limited in your material selection. Unlike machining, where you factor speed into your cycle time and cost, investment casting is compatible with virtually any alloy and your choice doesn’t change the speed of the process.</p><p>Do you need an alloy with specific strength, conductivity, elongation, or hardness requirements? Do you need to be able to test these requirements in a real-world setting before mass production? The wide alloy</p><h2>Surface finish testing</h2><p>Speaking of testing requirements, does your die cast component need to be able to withstand a corrosive environment or display high wear-resistance characterisitcs? Or would you like to test the longevity of an ornamental finish? Investment casting prototypes are an excellent option when you want to verify that your chosen surface finish or plating does not negatively affect the performance or the aesthetic of your end component.</p><p>Because of the nature of the ceramic shell used in the investment casting process, investment cast prototypes can maintain a repeatable standard surface finish of 125-150 RMS for most alloys. The smooth finish mimics that of a die cast component, and is therefore an accurate measure of how an additional coating or plating will perform on the part. </p><h2>Why is a fully functional prototype the best prototype?</h2><p>Testing with a fully functional prototypes allows you to effectively test for more demanding project requirements, rather than just proof of concept. The prototyping stage is important—it ensures a strong foundation for your product launch. We want to make sure that you get it right, the first time.</p><p><strong>Are you ready for effective prototyping? Get in contact  with one of our engineers, or visit our sister company, Signicast, to learn about their rapid prototyping capabilities.</strong></p>

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Learn how investment cast prototypes can streamline die casting production, providing accurate models for testing and design validation.

Investment Cast Prototypes for Die Casting | Dynacast

Investment casting is an ideal prototyping process for die cast components due to its ability to replicate the exact mechanical and physical properties of the final product, offer a wide range of alloy options, and test surface finishes, ensuring prototypes meet real-world testing standards and performance requirements.

Investment Cast Prototypes for Die Cast Components

<p>As the automotive industry increasingly designs and produces more sustainable, electronically-powered vehicles, <strong>manufacturers will need to adapt by converting traditionally ICE-compliant parts to be compliant with EV parts—this means higher voltage batteries, more efficient heatsinks, lighter weight components, and sustainably sourced materials.&nbsp;</strong>And with more and more automotive players moving to offer their customers hybrid and EV technology, now is the time to re-think part designs and effective materials to keep up with the automotive trends.</p><p>Although the events of 2020 significantly decreased demand for EVs and other automotive vehicles temporarily,<strong> the global electric vehicle market demand is expected to rise at a CAGR of 41.5% from 2022 to 2027</strong> -- with the market size expected to surpass US $718 billion by 2030.</p><h2><strong>The importance of reducing component weight in automotive and EV designs </strong></h2><h3>Benefits of aluminum in auto applications</h3><p>Aside from these factors, <strong>one major roadblock to widespread electrification is that it increases the vehicle’s curb weight—a development that needs to be countered by the use of lightweighting techniques.</strong> Lighter components make for lighter vehicles, which in turn improves energy efficiency for both electric and hybrid vehicles. Considering the rapid pace of development in electric powertrain, batteries, charge ports, and transmissions of electric vehicles and their impact on the weight of the vehicle, the need for suppliers with extensive experience and capabilities for lightweight manufacturing is on the rise.</p><p>That’s where aluminum comes in. Aluminum’s strength, corrosion resistance, low weight and heat dissipating properties offer mechanical designers significant advantages. Thin-walled aluminum castings are also able to withstand the highest operating temperatures of all die cast alloys. Specifically for the automotive industry, choosing alloys with these properties improves fuel efficiency of hybrid vehicles and allows both hybrid and electric cars to accelerate faster, brake quicker and handle better. </p><h3>Zinc as an alternative weight saving solution</h3><p>And in parts where weight is not a factor, zinc can be a great alternative. Because most engineers focus heavily on the weight of the actual material, zinc is often overlooked when it comes to lightweight die casting applications, when really, zinc could be a more economical choice.</p><p>Because of zinc’s greater fluidity, die castings can be made thinner, more intricate, and more complex, eliminating the need for secondary operations that are almost always necessary for aluminum and magnesium alloys. <strong>With less material being used in thin-wall applications, parts automatically become lighter, creating savings in material cost and energy—when melting and recycling.</strong></p><p>Another benefit of zinc is the extended die life it provides. Due to the low melting temperature of zinc die casting alloys, dies for zinc parts can last up to 10 times longer than dies used for aluminum and about five times longer than dies used for magnesium. When designing high-volume, complex components, zinc becomes extremely cost effective when considering the tooling investment.</p><h2>Die casting vital shielding components for increased electronic features</h2><p>Another roadblock in the EV industry is the need to handle the ever-increasing number of electronic sensors. Precisely cast, thin-walled housings are needed to position electronic componentry and other parts, like heat sinks, within a net-shape design. Die casting allows designs with internal features to be manufactured into the part without the need for additional operations, significantly increasing accuracy and saving on costly secondary processes. </p><p>As autonomous vehicles rise in popularity, sensors, radars, and cameras become increasingly advanced and critical to the function of the car. Alloys like zinc, with high wear resistance and structural integrity, make it perfect for the creation of the multi-faceted, highly complex shapes used in automotive safety and electronics components. Whereas alloys like aluminum, with high thermal conductivity and lightweight capabilities, make it the ideal material for battery packs, motor housings, and heat sink systems.  </p><h3>Processes and alloys matter</h3><p>As the EV and hybrid vehicle industry continue to rapidly grow, the importance of choosing the right manufacturing process and alloy are critical to not only the safety and performance of the vehicle, but also to the success and budget of the project. Lightweighting has many benefits, including reducing the energy consumption needed to propel heavy vehicles, and die cast alloys can also provide solutions for the increase in electronic components in vehicles with their net-shaped designs and thermal qualities. Contact our team on skilled engineers to embark on the design for manufacturing journey.</p>

Explore how die casting is transforming the automotive industry, with trends in lightweighting, performance, and cost efficiency for future vehicles.

Trends in Automotive Die Casting | Future of the Industry

Explore how the future of die casting in the automotive industry is driven by the need for lightweight, high-performance components in electric and hybrid vehicles, with a focus on innovative materials like aluminum and zinc to meet evolving design and efficiency requirements.

Medical

Healthcare Leaders Choose Dynacast To Help Achieve Key Goals

Ergonomic Designs

Biocompatible Materials

Strength and Durability

Complex Geometries

Industry Leading Certifications

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Elevate Your Knowledge About Die Casting for Healthcare

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Medical

Healthcare Leaders Choose Dynacast To Help Achieve Key Goals

Ergonomic Designs

Biocompatible Materials

Strength and Durability

Complex Geometries

Industry Leading Certifications

A Look AtMedical Applications

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Healthcare

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