<h1>A3 Machine Capabilities</h1><p>Dynacast’s machine capabilities are a key factor in our ability to deliver high-quality components. Our proprietary multi-slide technology enables fast cycle times and precision in our A2 machines, as discussed in a previous blog. This blog focuses on another machine type, the A3.</p><h2>A3 SIS</h2><p>The A3 SIS machine was introduced in 2010 and features a reinforced main plate with 28 tons of locking force. It can accommodate a die size up to 160 x 140 mm and a shot weight of up to 180 grams. Using the SIS injection system, the A3 SIS offers faster cycle times and increased cavity capacity compared to traditional machines. This machine excels at filling parts quickly, resulting in improved surface quality and reduced porosity. Its ability to handle four slides plus additional integrated options allows for more complex part designs.</p><h3>A3 MAG SIS</h3><p>The A3 MAG SIS machine shares the A3 SIS’s core specifications but includes a two-chamber melting pot for magnesium alloys. Designed for small, high-quality magnesium parts, this machine eliminates the need for machining and complies with CE safety standards. Similar to the A3 SIS, it offers faster cycle times, better handling of complex parts, and the ability to produce parts with thinner walls and tighter tolerances compared to traditional machines.</p>

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Learn how A3 die casting machines enhance part size flexibility, reduce cycle times, and maintain precision for larger components.

Benefits of A3 Die Casting Machines | Dynacast

Discover how Dynacast's A3 die casting machines deliver superior part quality, faster production, and greater complexity compared to traditional methods. 

Benefits of A3 Die Casting Machines

<p>High pressure die casting is a fast, repeatable process that delivers quality metal components, every time—but only if your component is designed properly. There are many factors that go into a successful design for high-volume manufacturing and our team of engineers helps thousands of customers each year successfully launch new projects.</p><p><strong>Keep reading to learn the answers to some of our most frequently asked questions about die cast design.</strong></p><p>When designing a part for die casting, many of our customers are looking to reduce not only the cost of their component but overall weight as well. To do this, our team looks at the component as a whole and utilizes our DFM (design for manufacturing) methods to design out inefficiencies. What does this mean for you? Your final part will be designed not only to your specific requirements but it will be a high-quality component that won’t fail you down the road.</p><h2>Die Casting Design Related Questions</h2><p>At the end of each of our MetalSolutions’ webinars, we leave time for attendees to ask questions to our presenter. Here are just a few of the questions that were asked during the design webinar that we feel would be helpful to others.</p><h3>What is the ideal wall thickness for die castings?</h3><p>Wall thickness, typically is 2mm for aluminum die casting. Customers are looking for lighter weight castings and a lot of times it depends on the thickness to length ratio. If you have a very long part, it is more difficult to have a very thin wall.</p><p></p><iframe src="https://www.youtube.com/embed/FidK9qbaD-o" width="636" height="406" title="Dynacast | Die Casting Manufacturer | Precision Metal Components" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen=""></iframe><h3>Should parting line flats have draft?</h3><p>They can, but they can also be straight. With smaller die castings, we can use vibratory tumbling. With a larger part, we typically design it to be to be trimmed via a trim die and then it is ideal to draft the gate or overflow edge. The draft minimizes the potential for the trim die blade to skive the side of the part.</p><h3>Is a venting required in die casting?</h3><p>Venting is always required in die castings. Dynacast uses mold flow analysis to determine the best areas for overflows and vents to create better quality parts.</p><h3>Beyond looking at wall thickness, what can be done to mitigate or eliminate porosity?</h3><p>There are two forms of porosity; gas and shrink porosity. Gas porosity is due to air entrapment within the casting. With mold flow, our designers can see where the air is likely to be trapped and can design the tool with strategically placed vents that can eliminate much of the air. Also during design, slight modifications to the part may allow the material to flow in an optimal flow pattern avoiding pockets and features that can cause turbulence entrapping air.</p><p>With shrink porosity, again using our mold flow software we can run a thermal analysis to isolate hot spots within a part during solidification. These hot spots can then be addressed with cooling channels in the die to help extract heat. Also, uniform wall thickness is always preferred. Having thin and thick cross-sections adds to longer solidification times that can create shrink porosity.</p><h3>How do surface finishes such as knurling and embossed letters impact tool life?</h3><p>The features don’t really impact the life of the tool. With zinc die castings you can get a million plus shots off the die blocks. A lot of times it’s the core pins that may wear, but Dynacast designs interchangeable inserts for features that wear faster than the tool.</p><p>Aluminum die castings can produce 150,000 shots depending on the requirements, but adding certain features won’t have a major impact.</p><p>Relative to plastic parts, are castings more tolerant of irregular wall thickness?<br />Yes, to the point that you will not see the sink marks. In plastic parts you are more likely to see a sink mark in cross-sectional areas. Metal alloys have surface tension that hold the integrity. Our engineers strive to always achieve uniform wall thickness, but in comparison to plastic, yes die castings are more tolerant of irregularities.</p><h2>Die Cast Design Expertise</h2><p>During our Die Cast Design webinar, we cover a variety of design techniques including:</p><ul><li>Parting lines 1</li><li>Core pins 2</li><li>Section lines 3</li><li>Flats</li><li>Parting lines on threads</li><li>Gating</li><li>Assist flow</li><li>Ribs</li><li>Wall thickness 2</li><li>Fillets and radii</li><li>Draft</li><li>Holes and slots</li><li>Knurling, lettering, and logos</li><li>And more!</li></ul><p>If you’re interested in learning more about designing a component for the die casting process, we invite you to download our design webinar and if you have any questions at all or would like to speak with a member of our team, we’d be happy to assist you.</p><p><strong>Fill out the form below to view our on-demand webinar. Discover our top design tips for improving product efficiency, extended tool life, and lowering part cost. </strong></p>

Explore our die casting design FAQ to understand critical design considerations, materials, and the most common industry queries.

Die Casting Design FAQ | Common Questions Answered

Explore essential tips and answers to frequently asked questions about die casting design to ensure high-quality, efficient, and cost-effective metal components for your high-volume manufacturing needs.

Die Casting Design FAQ

<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>

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. 

An Introduction to Precision Die Casting: Frequently Asked Questions

<p>Thixomolding is a technology for producing high-quality magnesium components, offering advantages such as improved part quality, less tool wear, and reduced energy use. Developed over 25 years, it uses solid metal chips heated into a semi-solid state and injected into a mold. This method ensures better control over material properties, including thinner walls, less porosity, and greater accuracy. Dynacast's Dynathixo technology enhances this process with a cold chamber system for optimal efficiency.</p><h2><strong>The Thixomolding Process</strong></h2><p>Thixomolding involves the following key steps:</p><ol><li><strong>Solid Chips</strong>: Instead of molten material, solid magnesium metal chips are loaded into the extruder.</li><li><strong>Compression and Heating</strong>: The chips are compressed and heated inside the extruder, where they transform into a semi-solid material.</li><li><strong>Injection</strong>: The semi-solid material is then injected into the mold cavity using the extruder as a piston, where it solidifies and forms the final part.</li></ol><p>This method allows manufacturers to create parts with enhanced mechanical properties, while the semi-solid nature of the material helps to reduce shrinkage and porosity.</p><h2><strong>Combining Thixomolding and Cold Chamber Technology with Dynathixo</strong></h2><p>While thixomolding has proven to be a highly effective casting method, Dynacast has taken this technology to the next level with Dynathixo. This advanced semi-solid metal casting process combines traditional thixomolding with cold chamber technology, offering significant improvements in production efficiency, part quality, and environmental impact.</p><p>The Dynathixo system features an extruder that mixes solid metal chips into the pressure chamber, which is then processed using a cold chamber plunger and hydraulic system. The result is a robust system that delivers excellent shot weight, and high-quality magnesium components.</p><p></p><figure style="text-align: center"><div data-img-caption-container="true" style="display: inline-block; text-align: center;"><img asset_uid="blt8d18edc78634c287" width="839" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt8d18edc78634c287/67ea9a53a83ed3095b785184/Dynacast_Additional_Capabilities_Thixomolding_Dendrit_Process.jpg" alt="Graphic showing how semi-solid metal chips are formed during the thixomolding process" height="498" style="max-width: 839px;width: 839px;height: 498px;text-align: center;" /></div></figure><p></p><h2><strong>Dynathixo’s Key Advantages</strong></h2><p>Dynathixo stands out for its ability to deliver high-performance parts with the following benefits:</p><ul><li><strong>Superior Material Properties</strong>: Dynathixo components benefit from enhanced strength and durability, making them ideal for high-performance applications.</li><li><strong>Reduced Tool Wear</strong>: The lower temperature at which the material is processed reduces wear on the tooling, extending tool life and minimizing maintenance costs.</li><li><strong>Improved Part Quality</strong>: The combination of thixomolding and cold chamber technology ensures that the final parts have thinner walls, reduced porosity, and greater dimensional accuracy compared to standard casting methods.</li><li><strong>Flexibility</strong>: Dynathixo machines can quickly be converted to cast aluminum via the cold chamber die casting process, offering versatility across different material requirements.</li><li><strong>Environmental Efficiency</strong>: The process operates at lower temperatures compared to traditional die casting, reducing energy consumption and CO2 emissions. Additionally, there is no need for inert gases, further improving the environmental footprint of the process.</li></ul><h2><strong>The Future of Thixomolding Manufacturing</strong></h2><p>As demand for high-performance, cost-effective, and sustainable components grows, Dynathixo is poised to play a critical role in meeting these needs. This innovative technology is set to revolutionize the way manufacturers approach magnesium die casting, offering a more durable alternative to traditional casting methods.</p>

Learn what Thixomolding is and how it enhances the die casting process by combining the benefits of injection molding and die casting techniques.

What is Thixomolding? | Die Casting Technology

The article explores thixomolding, a manufacturing process for high-quality magnesium components that enhances part precision, reduces energy consumption, and minimizes tool wear. It also highlights Dynacast's Dynathixo technology, which improves the process with a cold chamber system for greater efficiency and control.

Benefits of A3 Die Casting Machines

A3 Machine Capabilities

A3 SIS

A3 MAG SIS

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