Design for Manufacturing FAQ: Expert Insights

Designing for die casting requires a careful balance between part functionality, manufacturability, and cost efficiency. Questions like "How thin can the walls be?", "Where should gates be placed?", or "What's the best way to avoid porosity?" are common during product development, and that's where Design for Manufacturing (DFM) plays a critical role.

We sat down with Max Gondek, Senior Application Engineer at Dynacast, who holds a Mechanical Engineering degree from Purdue University and has over a decade of die casting experience. Below, Max answers the most frequently asked questions about DFM and how early collaboration with Dynacast can optimize part design, tooling, and overall production outcomes.requently asked questions about design for manufacturing below:

Why is Design for Manufacturing (DFM) Important?

Max Gondek: It's crucial to collaborate with a Dynacast engineer as early in the design phase as possible. Even small design tweaks can have a huge impact on part quality, tool life, and production efficiency.

DFM isn't about redesigning your part — it's about refining it. Minor adjustments like wall thickness uniformity, draft angles, and feature placement can drastically improve material flow, reduce cycle times, and eliminate costly secondary machining.

For example, by optimizing metal saver geometry and increasing uniform wall thickness, we've improved casting quality, extended tool life, and enhanced overall material flow, resulting in better, more consistent parts.

Does Dynacast Have a Dedicated Team for DFM Support?

Max Gondek: Absolutely. DFM is what we do every day. Our engineering teams specialize in analyzing casting designs and collaborating closely with customers to make data-driven recommendations.

We review each design based on alloy type, part size, tolerance needs, and quality requirements. Dynacast's global engineering network works together weekly, leveraging expertise from multiple facilities to deliver the best results.

We also use advanced casting simulation software (MAGMA) to model part performance, optimize gating and cooling, and predict potential issues before production ever begins.

How Does DFM Help Avoid Shrinkage Porosity?

Max Gondek: One of the biggest challenges in die casting is shrinkage porosity — small voids that form as metal solidifies and contracts. The key to minimizing porosity is maintaining uniform wall thickness and removing excess mass wherever possible.

By strategically using metal savers or weight savers, we promote even solidification and better metal flow. This reduces porosity, improves surface integrity, and speeds up cycle time, allowing more parts to be produced per hour and lowering overall part cost.

In short: uniform walls = uniform cooling = fewer defects.

How Does Draft Impact Part Design in Die Casting?

Max Gondek: Once the overall geometry is defined, adding draft (slight taper on walls) is the next crucial step. Draft allows the part to release cleanly from the tool without sticking or causing damage.

Think of old ice cube trays, and how the tapered sides make it easier to remove the cubes. The same principle applies to die casting. Without draft, you risk damaging the mold or part during ejection, which can lead to downtime and poor surface finishes.

After adding draft, we typically move on to radii, fillets, and rounds for further optimization.

What Are the Advantages of Fillets and Radii in Part Design?

Max Gondek: Sharp corners are stress concentrators and should always be avoided (except at the parting line). Fillets and radii:

• Improve metal flow and fill consistency
• Reduce stress concentrations
• Prevent cracking during solidification
• Extend tool life and improve part strength

Rounded transitions allow molten metal to flow more smoothly, minimizing turbulence and ensuring consistent material distribution across the part.

What If My Part Keeps Failing Testing? How Can DFM Help?

Max Gondek: Definitely — and this is a common scenario. When a part fails finite element analysis (FEA), the instinct is often to make the walls thicker. But thicker doesn't always mean stronger.

Instead of adding mass, we look for structural reinforcement opportunities: ribs, webs, gussets, and optimized load paths. These features increase rigidity without compromising flow or introducing porosity, ensuring that strength and manufacturability work hand in hand.

What Is the Function of Ejector Pin Bosses?

Max Gondek: Ejector pins physically push the finished casting out of the die after solidification. To prevent damage, parts often include ejector pin bosses — small, reinforced areas where these pins make contact.

Designing proper ejector pin bosses ensures smooth part ejection, protects delicate features, and supports automation during post-processing. We often integrate these directly into structural areas like ribs or heat sink fins.

Why Are Tolerances So Important in Die Casting?

Max Gondek: A flawless CAD model doesn't guarantee a manufacturable part. Even with the right draft and fillets, tolerances must align with die casting process limits.

We help customers evaluate:

• Parting-line design
• Tooling configuration
• Thermal effects and linear shrinkage
• Dimensional control and repeatability

Die casting inherently offers excellent repeatability and can often eliminate secondary machining — but only when tolerances are defined properly from the start.

How Does Material Selection Affect DFM?

Max Gondek: Material choice is just as critical as geometry. The right alloy affects everything from thermal conductivity and strength-to-weight ratio and surface finish.

Dynacast's Metal Selector Tool helps designers compare alloys like zinc, aluminum, and magnesium based on specific project needs. It allows real-time evaluation of thermal, mechanical, and density properties — helping engineers make informed, data-driven material decisions.

Key Takeaways: Why Early Collaboration with Dynacast Matters

• Involve DFM experts early to reduce rework and improve manufacturability
• Focus on uniform wall thickness to minimize defects
• Use draft, fillets, and ribs to enhance part strength and tool life
• Define tolerances and material choices based on real-world casting data
• Leverage simulation tools for optimal design validation

Design for Manufacturing isn't just an engineering checklist, but a strategic process that drives efficiency, consistency, and cost savings throughout the entire production cycle.

Dynacast combines decades of experience, precision engineering, and cutting-edge simulation to help customers design parts that are stronger, lighter, and easier to produce.

To learn more about our processes and best practices, check out our Dynacast FAQ page for additional insights into die casting design, materials, and manufacturing excellence.