<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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Healthcare Leaders Choose Dynacast To Help Achieve Key Goals

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<h2><strong>The Challenge: Plant Closure Opens a Complex Mission</strong></h2><p>When a long-established plant shut down, a leading player in the security products industry was faced with an urgent and complicated transition. The facility's aging infrastructure, high labor costs, and inefficient tooling utilization had made in-house production unsustainable. With most of the tooling contributing minimally to overall production spend, the decision was made to relocate dozens of tools—an ambitious move requiring speed, coordination, and technical precision.</p><p>But the road ahead wasn’t simple. Rising cost pressures, logistical strain from shipping dozens of tools monthly, and unclear tooling documentation posed real threats to success. On top of that, inconsistent sampling protocols and missing information for secondary operations risked slowing everything down.</p><h2><strong>The Solution: A Smart Shift to Efficiency and Control</strong></h2><p>Dynacast’s focus was not just on moving tools—it was on optimizing them for better performance and building a foundation for long-term value.</p><p>Dynacast brought deep <strong>expertise in precision casting</strong>, using an engineering-first approach to ensure every part was thoughtfully designed and accurately cast for optimal performance. This technical rigor was matched by <strong>speed without compromise</strong>—the team acted swiftly to meet tight timelines without ever cutting corners, maintaining the highest quality standards throughout. What truly set the project apart, however, was the <strong>partnership dynamic</strong>.</p><h2><strong>The Implementation: Prioritizing Medium-to-Low Volume Parts</strong></h2><p>Thanks to compatibility with the customer’s existing equipment platforms, the Dynacast team was able to integrate the transferred tools with minimal disruption—often getting machines running within a day or two. Dynacast focused efforts where it mattered most: medium-to-low volume parts that offered the greatest strategic value, while also keeping future high-volume opportunities in view.</p><h2><strong>Capabilities That Count</strong></h2><p>The equipment used at Dynacast represented a major upgrade from the aging machines of previous suppliers. Our ability to build both tools and machines in-house gave the team unique control over quality and lead times. And when added flexibility was needed, our collaboration with global teams—including engineering support from Asia—ensured nothing slowed progress.</p><h2><strong>The Results: Partnership, Performance, and Future Potential</strong></h2><p>Weekly check-ins, pilot runs, and a commitment to shared success laid the groundwork for a lasting strategic relationship. By avoiding supply chain disruptions during a critical transition, Dynacast not only ensured continuity but also improved tooling performance—extending tool life and setting the stage for future growth and opportunities.</p><p></p>

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Learn how Dynacast managed a complex tooling move after a plant closure, ensuring uninterrupted production and timely delivery.

Tooling Transfer After Plant Shutdown | Dynacast Case Study

In this case study, you'll see how Dynacast tackled the urgent challenges of a plant closure for a major security products company—moving dozens of tools quickly and precisely while improving overall efficiency. You'll learn how their engineering-first approach and close collaboration helped turn a complex transition into a long-term strategic win.

How Dynacast Orchestrated a Complex Tooling Move

<p>Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. </p>

Take a journey through the Dynacast Peterborough tool room. In-house die cast tool design offers companies greater flexibility, control, customization, and responsiveness. It streamlines the production process, improves collaboration between design and production teams, and contributes to long-term cost savings and product quality enhancement. 

Die Cast Tooling & Engineering Capabilities

<p>The die casting process can have significant advantages over other manufacturing processes—like machining and stamping—leading to major cost savings in piece price and overall cost of production. With die casting, you can create complex net-shapes, including complex internal and external features with minimal draft angles—minimizing secondary operations. But as with any production process, there is a lot to learn before making a decision on which process would be best for you component.</p><p>In January of 2021, Form Technologies hosted the first installment of Metal Solutions Webinar Series – EU. This webinar, An Introduction to Precision Die Casting, presented by the European Dynacast team, aims to guide our customers on how to take advantage of the benefits of die casting. Our webinars present attendees with the opportunity to ask our experts real questions about the die casting process during our live question and answer section. Take a look at some of the most frequently asked questions below.</p><h2>What is the minimum wall thickness for die cast components?</h2><p>The minimum wall thickness that we can achieve is dependent on the part geometry and part design, but in an ideal scenario, Dynacast can cast aluminum walls as thin as 0.3mm. Generally, a minimum wall thickness of 0.5mm – 1.0mm is advisable to maintain high strength.</p><h2>What is the ideal wall thickness for die casting?</h2><p>There is no one ideal wall thickness for a die casting component. Rather, it is exceedingly important to maintain consistent wall thickness and reduce weight where possible for a strong, cost-effective component. The best way to achieve this is to design optimized gate and overflow locations into your part design to avoid unnecessary porosity and maintain strength.</p><h2>What is the tightest tolerance Dynacast can hold?</h2><p>Dynacast prides itself on maintaining the tightest tolerances in the industry, but similarly to wall thickness, the tolerance is largely dependent on part geometry. For the most exact tolerances, generally between ±0.001” and ±0.002” is possible for zinc, whereas aluminum can hold between ±0.002” and ±0.004”.</p><p>However, even though a tolerance of ±0.001” is possible with Dynacast, manufacturers must be careful to avoid engineering unnecessary cost into the design. Too often, companies will request exacting tolerances and minimal draft angles when such features are not needed to maximize part performance. As a result, their castings fail.</p><p>Instead, take a more holistic approach to your design. With the help of our engineers, determine the non-critical dimensions of your component to allow for more lenient tolerance zones. In addition to extending the life of your tool since there are fewer exact geometries that wear down, allowing for tolerance zones also makes it easier to plan the tolerance stack-up of your entire component. This will help you to avoid machining and secondary operations wherever possible, making your design work for you to get the most out of the die casting process.</p><h2>Which die cast metals are environmentally friendly to use and produce?</h2><p>All of the die cast materials that we use, aluminum, zinc, and magnesium are environmentally friendly because they are recycled. At Dynacast, our plants work in a closed loop cycle, utilizing advanced re-melting capabilities to re-use any excess metal retrieved from our runner systems in the dies. After reclaiming the excess metal, Dynacast verifies the chemical composition with spectrometers to ensure that they maintain the physical and mechanical properties of newly sourced metal.</p><p>In terms of production, aluminum is the most environmentally friendly of all the die casting metals. Aluminum is 100% recyclable, and 75% of all the aluminum ever produced is still in use today. Since aluminum can be recycled again and again with no deterioration in its mechanical or physical properties, it can serve the same applications with the same level of performance as primary aluminum extracted directly from bauxite ore—all while having a positive impact on the environment and your bottom line.</p><p><em>The physical and mechanical properties of aluminum make it the ideal choice for parts that can be used in almost any industry, including aerospace, defense, consumer electronics, healthcare, automotive, and more. </em></p><h2>What are the benefits of die casting over screw machining?</h2><p>The benefits of die casting are largely associated with production speed and total piece price savings. Dynacast’s multi-slide machines can be designed with multiple cavities and enable our engineers to cast extremely complex parts, quickly. Our multi-slide die casting machines cycle at speeds of up to 75 cycles per minute, delivering 4,500 shots per hour. In a two-cavity tool, this means 9,000 parts per hour.</p><p>A faster cycle time contributes to lowered overall cost per piece. Additionally, die cast tools ensure unmatched complexity of internal and external geometries, so there are fewer secondary operations associated with die casting. With multi-slide die casting, you can cast complex geometries that would otherwise need to be manufactured from two or more pieces and assembled using any other processes.</p><p>While screw machining offers a lower up-front tooling cost, die casting more than makes up for that in the overall peice price savings. On an ideal part (one that is small, high volume, and can be cast in zinc), the tool is paid back in full somewhere between 10-14 months of production. Every part made after that is an earning towards your bottom line.</p><h2>Do you have materials that are corrosion resistant without surface treatment?</h2><p>The level of environmental resistance offered depends on the material and your project requirements. Zinc, for example, is relatively self-resistant in comparison to aluminum alloys, but you will get some zinc oxide, or white rust. However, if you need a high level of environmental resistance for your die cast component, we recommend utilizing one of our surface treatments—from treatments and coatings that offer corrosion resistance, high-gloss finishing, painting, and more.</p><h2>How can you determine if die casting is cost effective compared to other fabrication processes?</h2><p>The cost effectiveness of the die casting process needs to be evaluated on a case-by-case basis. There are many cases in which converting to die casting from screw machining, machining from solid, stamping, and welding results in better part performance and better cost at full-scale production. However, we invite you to contact an engineer to determine if converting to die casting is the best solution for you.</p><p>With over 80 years of experience, Dynacast consistently delivers value through engineering expertise, efficient operations, and Advanced Quality Planning systems. <strong>If you’re interested in learning more about the die casting process or Dynacast’s unique capabilities, sign up for our free on-demand seminar and view at your convenience.</strong></p>

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Get answers to common questions about precision die casting, including benefits, tolerances, materials, and design flexibility.

Precision Die Casting FAQs | Dynacast Guide

See insights into the benefits and considerations of precision die casting, addressing common questions to help manufacturers optimize production and cost efficiency. 

Medical

Healthcare Leaders Choose Dynacast To Help Achieve Key Goals

Ergonomic Designs

Biocompatible Materials

Strength and Durability

Complex Geometries

Industry Leading Certifications

A Look At
Medical Applications

BEYOND THE BASICS

Elevate Your Knowledge About Die Casting for Healthcare

Case Study

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Article

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Interested in starting your die casting journey?

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

Case Study

Video

Article

Global Reach, Local Expertise

Interested in starting your die casting journey?

A Look At
Medical Applications