<h1>Design Tips for Improved Die Casting</h1><p>Die casting is a versatile manufacturing process capable of producing a wide range of parts from various metals. To optimize part design and achieve optimal results, consider these essential tips.</p><h2>Die Casting Variables</h2><p><strong>Draft:</strong>&nbsp;Incorporating draft, a slight taper on part walls, is crucial for easy casting removal and to compensate for shrinkage. Aim for a draft angle of ¼ to 1 degree per side, adjusting as needed based on alloy and process.</p><p><strong>Fillets and Radii:</strong>&nbsp;Generous fillets and radii enhance part strength, improve metal flow, and simplify finishing. Implement them whenever possible.</p><p><strong>Ribs and Bosses:</strong>&nbsp;While ribs and bosses increase part strength, ensure they blend seamlessly with fillets and radii to avoid sharp corners. Apply draft to non-critical surfaces.</p><p><strong>Pockets:</strong>&nbsp;Reduce part weight and cycle time by incorporating pockets into solid sections. Maintain proper draft and radii for optimal results.</p><p><strong>Optimizing Material Flow:</strong>&nbsp;Facilitate metal flow by designing parts with smooth corners and uniform sections. While challenging in some cases, minimize restrictions like long slots and maximize flow with round holes.</p><h3><strong>Additional Considerations</strong></h3><p>Explore the full potential of the die casting process by incorporating features like logos, textures, integrated fasteners, and embossed part numbers. Dynacast’s 4-slide die casting process offers even greater flexibility.</p><p>Dynacast provides a comprehensive design for manufacturing&nbsp;(DFM)&nbsp;service to help optimize your part design for die casting and cost-effectiveness.</p>

Manufacturing employee operating equipment in Peterborough

Dynacast_Resources_Articles.png

Enhance die casting efficiency and part quality with Dynacast's expert design tips, focusing on manufacturability and cost-effective production.

Design Tips for Improved Die Casting | Dynacast Article

See essential design tips for optimizing die casting parts.

Design Tips for Improved Die Casting

<p>At Dynacast all of our machines need to meet certain standards. As a machine ages, technologies can become outdated and parts can wear. This blog post will give you an inside look at how we keep our machines up and running, and how we upgrade them to ensure the most up-to-date technology is available for our customers’ manufacturing needs.</p><h2>Why is regular maintenance essential?</h2><p>Regular maintenance is crucial for several reasons. Well-maintained machines operate more reliably, reducing downtime and production disruptions. Up-to-date equipment often offers improved efficiency, leading to higher output and lower costs. Adhering to maintenance schedules helps ensure compliance with industry regulations and safety standards. Upgrading machines allows us to incorporate the latest technologies and stay competitive in the market.</p><h2>How do we handle machine breakdowns?</h2><p>While we strive to prevent breakdowns, we are prepared to address them promptly. Our proactive maintenance programs, coupled with a robust inventory of spare parts, minimize downtime. In the event of a breakdown, we can quickly identify and replace faulty components, ensuring minimal disruption to production.</p><p>Accommodating Special Requests (H3)</p><p>Dynacast is equipped to handle special projects and components. Our specialized tooling and machinery enable us to efficiently produce complex parts and meet unique customer requirements. We can also customize machine programming to accommodate specific functions or tolerances.</p>

Explore how Dynacast's precision die casting machines deliver superior part quality and efficiency, advancing manufacturing processes.

Precision Die Casting Machines | Precision Meets Progress

Dynacast prioritizes machine maintenance and upgrades to ensure optimal performance, minimize downtime, and deliver high-quality products. 

Precision Meets Progress: Machine Upgrades

<h1>Multi-Award Winning Die Casting Facility</h1><p>Dynacast Elgin creates over a million precision zinc and aluminum die cast components each day from their 112,000 square foot facility. While that number alone is impressive, the real story lies in the people who and the number of award-winning components this facility has produced. We believe that the foundation of any successful project lies within the component design. For Dynacast Elgin that starts with their engineering team, winners of two International Die Casting Design Awards this past year.</p><p>While the award-winning components were created for automotive applications, each had very different functions and both were previously produced using a different manufacturing process. The over 6oz category winner was previously a machined aluminum extrusion assembly. The engineering team designed the part into a single component, utilizing Zamak 3 that incorporated necessary mounting features. The under 6oz category winner was previously a stamped component. Utilizing the facilities’ state-of-the-art software, the Elgin engineering team modified this part and designed it for the die casting process resulting in a higher strength component than the previously stamped version. Both redesigns reduced the overall part cost for the customer.</p><p>The team takes pride in helping customers determine the best materials and processes to deliver the best results for their business. They are driven to produce any component that customers bring to the table. With over 12 NADCA die casting awards, the Elgin engineering team has proven successfully their design for manufacturability techniques can create components other die casters simply cannot.</p><h2>In-House Capabilities</h2><p>Utilizing design, prototyping and modeling services, Dynacast Elgin provides manufacturing solutions to customers all over North America. Not only does Elgin build their tools in-house, they also run 9 aluminum die casting machines and 76 multi-slide zinc die casting machines—ranging from 4-600 ton locking force and part size varying from 1g to 7lbs. In addition to the wide array of die casting machines, Elgin has over 25 CNC machines—plus dedicated tapping, reaming, and drilling machines—far exceeding the capabilities of other die casters.</p><p>Additionally, Elgin’s specialty secondary manufacturing department and their robust network of certified suppliers supports many best-in-class manufacturers from a variety of industries including medical equipment &amp; devices, telecommunications, consumer electronics, and automotive—both electronics and safety-critical components.</p><h2>Operational Excellence</h2><p>Elgin was one of the first Dynacast facilities to implement FOS (Form Technologies Operating System.) The FOS platform incorporates a coordinated set of procedures for identifying problems, implementing changes, and developing easily repeatable systems that can be adopted into everyday practices. By utilizing 5S and other lean manufacturing techniques, Elgin has drastically improved the overall performance of the plant resulting in a positive impact on their customers. This new philosophy is not just a strategy implemented by management but a culture that has improved their way of thinking allowing them to maximize productivity and reduce waste.</p><p><em>Dynacast Elgin is the recipient of the NADCA safety award for achieving an outstanding record that exceeds national manufacturing averages. </em></p><h2>Midwest NAFTA Die Casting Company</h2><p>Dynacast Elgin is a NAFTA certified die caster that works with organizations all over the world, helping bring their ideas to life with the highest quality die cast components around the globe. Utilizing only certified alloys, Elgin delivers the results their customers need with the cost-effectiveness their business demands. Learn how to simplify your die casting process and reduce costs, contact Dynacast Elgin today to speak with someone from their local team or request a plant tour.</p>

Explore the capabilities of Dynacast’s Elgin facility, specializing in high-precision die casting and advanced manufacturing solutions.

Dynacast Elgin Facility Spotlight | Advanced Die Casting

Dynacast Elgin, a multi-award-winning die casting facility, produces over a million precision zinc and aluminum components daily, driven by a skilled team known for their innovative designs, extensive in-house capabilities, and commitment to operational excellence. 

Facility Spotlight: Dynacast Elgin

<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>

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. 

Design Tips for Improved Die Casting

Design Tips for Improved Die Casting

Die Casting Variables

Additional Considerations

Interested in starting your die casting journey?