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Dynacast - Resources - L1

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<h1>An Introduction to Precision Die Casting</h1><p>Dynacast, a Form Technologies Company, is a global manufacturer of precision, engineered metal components. Utilizing proprietary die cast technologies, we offer robust solutions to many industries including automotive, consumer electronics, and healthcare. </p><p>Every organization we work with benefits from over 80 years of experience, innovation, and techniques that have redefined the manufacturing industry. Dynacast operates 21 manufacturing facilities in 16 countries, and consistently delivers value through engineering expertise, efficient operations, and Advanced Quality Planning systems.</p><p>Join us for the initial installment of the Dynacast Metal Solutions Webinar Series - Europe. In this webinar, our team will cover:</p><ul><li>Material options</li><li>Die casting technology</li><li>Innovations in die casting showcase</li><li>Case studies</li><li>And more!</li></ul><p></p>

Manufacturing employee operating equipment in Peterborough

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Discover Dynacast's proprietary die casting technologies and how high-quality engineering, tooling, and process controls contribute to superior components.

An Introduction to Precision Die Casting | Dynacast Webinar

Join us for the Dynacast Metal Solutions Webinar Series - Europe as we explore material options, die casting technology, and innovative solutions in precision die casting, drawing on over 80 years of expertise to deliver cutting-edge insights and case studies. 

An Introduction to Precision Die Casting

<h1>Work Smarter. Not Harder.</h1><p>Design for manufacturing (DFM) is a Dynacast core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations, which can often represent as much as 80% of the component cost. In other words, DFM enables design engineers to work smarter, not harder.</p><p>Modifying your part design to take advantage of the die casting process not only enables you to fully leverage the efficiencies of die casting, but can also better suit your business needs. Learn about the benefits of die casting and optimizing your component for manufacturability in our webinar, where we’ll cover:</p><p>Design for manufacturing core concepts</p><ul><li> Eliminating inefficiencies</li><li>Component optimization for lowered part cost</li><li>Extending tool life</li><li>The importance of early engineer involvement, and more!</li></ul><p><strong>Fill out the form to download our free on-demand webinar.</strong></p><p></p>

Learn how to reduce component costs and optimize designs with our on-demand webinar on Design for Manufacturing (DFM). 

Removing Cost in the Design Stage | Dynacast Webinar

Discover how Design for Manufacturing (DFM) can streamline your design process, reduce component costs, and enhance tool longevity in our on-demand webinar, where we'll explore core DFM concepts, inefficiency elimination, and the benefits of early engineer involvement. 

Removing Cost in the Design Stage

<h2>Multi-Slide. Multi-Solution. Die Casting.</h2><p>Ask any engineer and they’ll tell you; great tool design is critical to the success of die cast components. One of the best options for creating small, complex parts is through the use of multi-slide tooling. Multi-slide is designed to use four (or more) perpendicular slides in the tool, thus creating more complex and accurate castings. </p><p>Multi-slide offers a number of unique advantages, including:</p><ul><li>Net shape first time, eliminating secondary operations like assembly and machining</li><li>Complex geometry and tight tolerances at high speed for world-class productivity and lower total costs</li><li>Minimum part-to-part variation compared to standard multi-cavity dies</li><li>More compact tools that are less prone to parting-line variation and its negative effect on the ﬁnished part’s dimensional tolerances</li></ul><p><strong>Multi-Slide. Multi-Solution. Die Casting.</strong></p><p><strong>When:</strong> On-Demand</p><p><strong>Presenters:</strong> Sergio Perino and Marc Boettcher </p><p></p><p></p>

Learn about achieving net shape accuracy, handling complex geometries, reducing part-to-part variation, and leveraging compact tooling for optimal results. 

Dynacast Webinar | Multi-Slide. Multi-Solution. Die Casting.

Explore the benefits of multi-slide tooling for die casting, including net shape accuracy, complex geometry, minimal part-to-part variation, and compact tools, in our on-demand webinar with Sergio Perino and Marc Boettcher. 

Multi-Slide. Multi-Solution. Die Casting.

<h2>Higher quality and cost savings with die casting</h2><p>The die casting process is ideal for producing extremely complex components at high volumes. While other manufacturing processes like machining, stamping, or spin casting may offer quality or volume, die casting delivers both. How?</p><p>The key lies in world-class process controls and superior automation.</p><p>We’ve covered the foundations of die casting technologies, and now we want to showcase our state-of-the-art processes and automation in real time. With advanced automation, Dynacast delivers reliability, cost savings, and improved part performance.</p><p>Discover how our automation reduces risk, cuts costs, and accelerates production by watching our on-demand webinar, featuring videos of our technology in action. In this webinar, we cover:</p><ul><li>Automated die casting processes</li><li>How automation removes added costs and risk</li><li>How automation speeds up component delivery</li><li>And more!</li></ul><p>Fill out the form to access our free on-demand webinar.</p><p><strong>For the best experience, please use Google Chrome, Safari, or Firefox. This webinar will be presented in English.</strong></p><p></p>

See die casting technology in action with a live virtual demo showcasing processes, tools, and production capabilities.

Live Die Casting Tech Demo | Dynacast

Join this webinar showcasing how advanced automation in die casting enhances quality, reduces costs, mitigates risks, and accelerates production through real-time demonstrations of cutting-edge processes. 

Die Casting Technologies in Action: Virtual Demonstration

<h2>Power of Precision </h2><p>Are you new to precision die casting or a veteran with years of expertise? And staying ahead of the game when it comes to precision die casting is critical. With die casting, you can create complex net-shapes, including complex internal and external features with minimal draft angles-minimizing secondary operations. <br /> <br />Join us as the Dynacast Europe team presents Precision in Production: Die Casting Capabilities. In this webinar, our team will cover: </p><ul><li>Die casting technologies</li><li>Material options</li><li>Design capabilities</li><li>Case studies</li><li>And more!</li></ul><p><strong>Precision in Production: Die Casting Capabilities</strong><br /><strong>When: On-Demand</strong></p><p><strong>** Note this webinar is presented in English.**</strong></p><h2>Fill out the form to watch our free webinar on-demand.</h2>

Understand how precision die casting delivers complex geometries, tight tolerances, and superior quality.

Precision in Production: Die Casting Capabilities

Bernd Froehlich

Sergio Perino

Christian Flich

Discover the cutting-edge die casting technologies, material options, and design capabilities in 'Precision in Production: Die Casting Capabilities 

Precision in Production Die Casting Capabilities

<h1>Overcome Die Casting Defects</h1><p><strong>Join our exclusive webinar on advanced techniques and solutions. </strong></p><p><br />Struggling with die casting defects that impact your production efficiency and product quality? Looking for expert guidance to optimize your die casting processes? <br />Join our highly informative and engaging webinar, "Overcome Die Casting Defects." Gain the knowledge and techniques to identify, prevent, and resolve common die casting defects. </p><p>Why Attend? </p><ul><li>In-Depth Knowledge: Defects, causes, troubleshooting. </li><li> Advanced Techniques: Minimize defects, optimize parameters. </li><li>Interact with Experts: Engage directly with our panel of die casting experts.  </li><li>Drive Efficiency and Savings: Improve efficiency, achieve cost savings. </li></ul><p><strong>Webinar Details: </strong></p><ul><li><strong>Overcome Die Casting Defects </strong></li><li><strong>When: </strong>On-Demand<br /></li></ul><p>Who Should Attend? Ideal for die casting engineers, manufacturing managers, quality control personnel, and professionals involved in die casting. Valuable insights and practical solutions for beginners and experts alike. <br /> <br />Secure Your Spot Now! </p>

Explore common die casting defects and discover practical solutions to improve product quality.

How to Overcome Common Die Casting Defects

Rodrigo Ballesteros

Sr. Business Development Manager

Max Gondek

Sr. Applications Engineer

Explore advanced techniques and expert strategies for identifying, preventing, and resolving die casting issues, enhancing production efficiency and product quality. 

Overcome Die Casting Defects

<p>Are you facing challenges with your die casting tooling? Whether it's supplier issues, the need for onshoring, or simply optimizing your production, transferring tooling can be complex. Join our free webinar, "Smooth Transitions: Mastering Die Cast Tooling Transfers," to learn how we simplify this process for you.</p><p><strong>In this webinar, you'll discover:</strong>&nbsp;</p><ul><li><p>How to streamline your die cast tooling transfers for maximum efficiency.&nbsp;</p></li></ul><ul><li><p>Strategies for successful onshoring and consolidation of your die casting operations.&nbsp;</p></li></ul><ul><li><p>Best practices for risk mitigation and ensuring supply chain security.&nbsp;</p></li></ul><ul><li><p>Real-world case studies showcasing successful tooling transfers.&nbsp;</p></li></ul><p><strong>Featured Case Studies:</strong>&nbsp;</p><ul><li><p><strong>Safety-Critical Transfers:</strong> Learn how we helped a leader in safety-critical components seamlessly transfer numerous tools while maintaining impeccable quality and reliability.</p></li></ul><ul><li><p><strong>Rapid Response and Onshoring:</strong> Discover how we enabled a solar mounting company to rapidly onshore production to meet surging demand and take advantage of federal incentives.</p></li></ul><ul><li><p><strong>Consolidating Production:</strong> See how we helped a major lock manufacturer consolidate a large number of tools from their in-house operations, preventing potential disruptions and ensuring a smooth transition.</p></li></ul><p><strong>Why Attend?</strong>&nbsp;</p><p>Transferring die cast tooling can be a daunting task, but with the right partner, it can be a smooth and efficient process. This webinar will provide you with the knowledge and insights you need to make informed decisions and avoid costly mistakes. We'll share our proven methodologies, best practices, and real-world examples to help you achieve your production goals.&nbsp;</p><p><strong>Webinar Details:</strong>&nbsp;</p><ul><li><p><strong>Date:</strong> May 1, 2025&nbsp;(previously April 17, 2025)</p></li></ul><ul><li><p><strong>Time:</strong> 2pm EST&nbsp;</p></li></ul><p><strong>Who Should Attend?</strong>&nbsp;</p><p>This webinar is ideal for manufacturing engineers, purchasing managers, supply chain professionals, sourcing.</p><p></p><p></p>

Learn best practices for managing die cast tooling transfers and ensuring production continuity.

Die Cast Tooling Transfers Guide | Dynacast

Are you facing challenges with your die casting tooling? Whether it's supplier issues, the need for onshoring, or simply optimizing your production, transferring tooling can be complex. Join our free webinar.

Smooth Transitions: Mastering Die Cast Tooling Transfers

<p>We understand that customers are under more pressure than ever to redesign components that keep up with rapidly changing technology and sustainability regulations. Many customers go about this by retrofitting past designs because it is the quickest and easiest way to production.</p><p>However, what customers fail to realize is even though their materials and designs may meet regulations and pass testing, there are more advanced and efficient options for manufacturing.</p><p>Register for this webinar to learn how die casting lends itself to solving some of the biggest challenges in manufacturing today. Also, we cover solutions for the following trends:</p><ul><li>Evolving technologies</li><li>Demand for skilled workers</li><li>Rising raw material price</li><li>Sustainability efforts</li><li>Changing regulations</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p>

Explore manufacturing strategies and die casting solutions that address today’s evolving market demands.

Solving Market Challenges with Die Casting

Discover how die casting can help you navigate evolving technologies, sustainability efforts, rising costs, and other key manufacturing challenges. 

Manufacturing Solutions for Evolving Market Challenges

<h1>Innovations in Precision Die Casting</h1><p>Casting may be one of the oldest forms of metal manufacturing, but the techniques being utilized today are far from old-fashioned. In fact, they are continuously being developed and improved.</p><p>Download our online seminar where we will discuss the most recent innovations in precision die casting. In this seminar, you will learn about the advanced technologies Dynacast uses to manufacture more than 5 billion components annually for customers across almost every industry.</p><p>We'll cover:</p><ul><li><strong>Advanced casting machines and techniques</strong></li><li><strong>Tooling and engineering expertise with customer case studies</strong></li><li><strong>Custom alloys</strong></li><li><strong>Cosmetic plating and coating</strong></li><li><strong>And more!</strong></li></ul><p><strong>Fill out the form to download the webinar.</strong></p><p></p>

Explore new technologies and innovations shaping the future of precision die casting techniques.

Precision Die Casting Innovations | Dynacast

Discover the latest advancements in precision die casting, including cutting-edge machines, innovative tooling techniques, custom alloys, and more, in our informative webinar by Dynacast. 

Innovations in Precision Die Casting

<h1>Tool Quality, Tool Maintenance, and Tool Replacement</h1><p>When it comes to being a successful manufacturer, you want to get the most value out of each step of your production process, and it can be tempting to cut corners. Without knowing much about the importance of tooling, some manufacturers can slip into the trap of cutting cost with cheaper molds.</p><p>Great tool design is critical to the overall success of your project. No matter how advanced your die cast machines are, if you cut costs for a cheaper tool, you run the risk of creating mediocre parts, adding costs with unnecessary secondary operations—or worse, complete project failure.</p><p>Sign up for our free on-demand webinar and learn about the importance of quality tooling to see the most ROI on your project, how to properly maintain a tool, and when it’s necessary to replace your die cast mold. In this webinar, we’ll cover</p><ul><li>What makes a quality tool</li><li>Dynacast tool maintenance standards</li><li>Designing to prolong the life of your tool</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p><p></p><p></p>

Discover how to maintain, replace, and ensure the quality of die casting tools for optimal performance.

Die Casting Tools: Quality and Maintenance Tips

Die Casting Tools: Quality, Maintenance, Replacement

<p>When it’s time to choose materials for your die cast component design, how will you decide which metal to use?</p><p>Before you go too far in your design, it helps to learn a bit about each of the options readily available for manufacture. Download our on-demand seminar to learn from our metals expert about <strong>Die Cast Material Options </strong>to give you a top-level view of the choices you’ll need to make, including a full list of alloys and our free interactive process and metal selector.</p><p>Fill out the form to access our free webinar! </p>

Understand die casting materials and learn how to select the best option for your application needs.

Choosing the Right Die Casting Materials

Learn about various die casting material options and get expert insights to help you choose the right metal for your component design in this on-demand seminar. 

Die Casting Materials

<p>Want to hear from some of the best design engineers within the die casting industry? Download our Die Cast Design Roundtable and hear from our multi award-winning engineering team!</p><p>Learn more about designing the best part possible with our unique design for manufacturing approach and hear first-hand how we won not one but two NADCA design awards last year! PLUS see this year's award winning design.</p>

Get expert insights on die casting design challenges and practical solutions for complex projects.

Insights from the Die Cast Design Roundtable

Access our on-demand Die Cast Design Roundtable to hear insights from award-winning design engineers on creating optimal die castings, including a showcase of this year's award-winning design. 

Die Cast Design Roundtable

<h2>Design engineering is changing and it’s changing fast.</h2><p>Today’s engineers are under a lot of pressure to get a viable component quickly and more efficiently than ever before. And Design for Manufacturing (DFM) discussions with your supplier are one of the best practices engineers follow to ensure proof of concept, part optimization, and scalability.</p><p>Outlining a successful plan and process for your part is just as important as the component itself. The design is crucial to the entire production process—and impacts everything from material cost to time-to-market.</p><p>In this webinar, <strong>Design for Manufacturing: A critical step for successful production, </strong>Dynacast’s Senior Application Engineer, Max Gondek, discusses the benefits of working with an engineer early in the design phase of your die cast part. He covers:</p><ul><li>How to reduce weight on components</li><li>Why wall thickness adds to cost</li><li>What the best draft angle is for your part</li><li>How to strengthen your casting with fillets and radii</li><li>And many more design tips!</li></ul><h2>Fill out the form to sign up for our free webinar.</h2><p></p>

Learn how design for manufacturing (DFM) boosts quality and efficiency in die casting production.

DFM: Key to Successful Die Casting Production

In this on-demand webinar, Dynacast’s Senior Application Engineer, Max Gondek, reveals essential Design for Manufacturing (DFM) strategies to optimize component design, reduce costs, and improve production efficiency through early collaboration with engineers. 

DFM: A Critical Step for Successful Production

<p>Aluminum die castings are often a top choice due to their corrosion resistance, strength, and thermal conductivity. But the castability of zinc, its thin-walled capabilities, and structural integrity make it the <strong>perfect alternative to aluminum</strong> in certain applications. </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 with aluminum. With less material being used in thin-wall applications, parts automatically become lighter, creating savings in material cost and energy. </p><p>To learn more, download our free webinar Zone in on Zinc: The alternative to aluminum. In this webinar, Max Gondek and Adam Scichitano of Dynacast will cover the following benefits of die casting in zinc: </p><ul><li>Tighter tolerances </li><li>Faster cycles times </li><li>Lower cost </li><li>Longer tool life </li><li>Medical case studies </li><li>Telecommunications/5G applications  </li><li>And more! </li></ul><p>Fill out the form to access our free webinar! </p>

Compare zinc and aluminum for die casting. Learn when zinc is the better choice for strength, detail, and cost-efficiency.

Zinc vs. Aluminum Die Casting | Dynacast

Discover why zinc die casting can be a superior alternative to aluminum for thin-walled, intricate parts in our free webinar. 

Zone in on Zinc: The alternative to aluminum

<h2>Three innovative technologies that deliver solutions</h2><p>The die casting process can have significant advantages over other manufacturing processes. With die casting, you can cast net-shape components to minimize secondary operations and consolidate multiple parts into a single component, allowing you to:</p><ul><li>Eliminate unnecessary assembly operations</li><li>Streamline your supply chain</li><li>Simplify stock control</li><li>All while gaining greater performance and part-to-part consistency</li></ul><p>But what technologies make that possible?</p><p>Dynacast is home to three innovative technologies that solve common manufacturing problems: <strong>multi-slide die casting, injected metal assembly, and center gate technology.</strong> Struggling with consistent part quality at high volume? Multi-slide die casting could be the solution for you. Looking for a better, longer-lasting assembly method for similar or dissimilar materials? Look no further than injected metal assembly. Have a component that needs complex external threads? Learn more about our center gating technology.</p><p>Submit your information below for access to our free webinar on "Three Technologies that Solve Common Manufacturing Problems." In this webinar, our presenters discuss how die casting answers the call when other processes fail to deliver solutions.</p><h2>Fill out the form to sign up for our free webinar.</h2><p></p>

Uncover three key technologies that resolve common manufacturing issues in design, production, and assembly.

How To Solve Manufacturing Issues | Dynacast

Discover how Dynacast's multi-slide die casting, injected metal assembly, and center gate technology address common manufacturing challenges and enhance efficiency in our free webinar. 

Three Technologies that Solve Common Manufacturing Problems

<h2>Sustainable Die Casting for a Better Environment</h2><p>At Dynacast, we recognize the challenges organizations face as they shift towards sustainability. We understand the complexities involved in this transformation especially for manufacturing. That is why we are adapting to meet the growing demand for sustainable die casting solutions.<br />Our commitment to sustainability is exemplified by our efforts in recycled zinc and aluminum die casting, plant process improvements, and environmental commitments. We are not just embracing the change; we are casting the way. <br /> <br />Join us as the Dynacast Europe team explores the future of sustainable die casting. Discover how sustainable practices can reshape precision die casting:</p><ul><li>Eco-friendly partnerships in die casting: Understand the importance of partnering with environmentally conscious companies meeting the demands of companies looking to achieve sustainability goals for 2030 and beyond.</li><li>Renewable energy: Learn how our solar panel implementation reduces our carbon footprint and dependence on fossil fuels.</li><li>Metal recycling: See how we recycle aluminum and zinc, reducing energy consumption and waste generation.</li><li>Case studies in sustainable die cast part solutions </li><li>And more!</li></ul><p><strong>Sustainable Die Casting for a Better Environment </strong><br /><strong>When: On-Demand</strong></p><h2>Fill out the form to watch our free webinar on-demand.</h2>

See how sustainable die casting practices can lower emissions, reduce waste, and contribute to a greener future.

Sustainable Die Casting | Dynacast

Vice President of Sales

Roman Hartl

Business Development Manager

Mathew Wallace

FP&A Manager

Discover how Dynacast is pioneering sustainable die casting with eco-friendly practices, renewable energy, and metal recycling to reshape the future of precision manufacturing in our on-demand webinar. 

Sustainable Die Casting for a Better Environment

<p>Download our free webinar, Surface Finish 101 to discover insights on many different casting finishes. From utility and functional grade to commercial and consumer grade coatings—including decorative finishes—we will walk you through the considerations you should be making before selecting a surface finish as well as tips for process control.</p><p>Fill out the form to access our free webinar! </p>

Learn about the importance of surface finish in die casting and how it affects aesthetics, performance, and durability.

Die Casting Surface Finish Basics | Dynacast

Explore the essential insights on various casting finishes—from functional to decorative—by downloading our free on-demand webinar, Surface Finish 101. 

Surface Finish 101

<p>Looking for a manufacturing solution that can join two or more dissimilar components together? Our injected metal assembly (IMA) process is a method that provides a permanent reliable bond by injecting a small amount of molten zinc around the components being joined.</p><p><strong>Learn more about IMA by downloading our webinar!</strong></p><p>We’ll cover:</p><ul><li>The IMA process</li><li>The advantages of utilizing this innovative bonding method</li><li>Materials you can join using the IMA process</li><li>Applications and solutions for a variety of industries</li></ul><p><strong>Fill out the form to access the webinar! </strong></p>

Learn about Injected Metal Assembly (IMA), how it works, and how it improves part strength, precision, and speed.

What Is Injected Metal Assembly? | Dynacast

See how our Injected Metal Assembly (IMA) process creates a permanent, reliable bond by injecting molten zinc around dissimilar components—perfect for a wide range of industries. 

Injected Metal Assembly

<h2>Dive into the Benefits of Die Casting</h2><p>Are you new to precision die casting or a veteran with years of expertise? Staying ahead of the game when it comes to precision die casting is essential. Learn why die casting is often more cost-efficient than other manufacturing processes, offering not only part price savings, but also major reductions in overall production cost! </p><p>With die casting, you can create complex net-shapes, including complex internal and external features with minimal draft angles-minimizing secondary operations. <strong>This webinar aims to guide our customers on how to take advantage of the benefits of die casting.</strong></p><p>Join us as the Dynacast Europe team presents <em>Dive into the Benefits of Die Casting</em>. In this webinar, our team will cover:</p><ul><li>Die casting technologies</li><li>Material options</li><li>Design capabilities</li><li>Case studies</li><li>And more!</li></ul><p><strong>Die Casting Unpacked</strong></p><p><strong>When:</strong> On-Demand</p><p><strong>Where:</strong> Online – join from anywhere!</p><p><strong>Presenters:</strong> Christian Flich, Sergio Perino, Bernd Froehlich</p><p><em>** Webinar is presented in English.**</em></p><h2>Fill out the form to watch our free webinar on-demand.</h2><p></p>

Dive into the fundamentals of die casting—from material flow to cooling and ejection—in this beginner-friendly overview.

Die Casting Process Explained | Dynacast

Explore the cost-efficiency and design flexibility of precision die casting with Dynacast Europe’s expert team in our on-demand webinar 

Die Casting Unpacked

<h3>Precise . Efficient . Versatile</h3><p>We have produced billions of zinc die cast components—from one hundredth of a gram to one kilogram in size. With the help of our engineering team, our customers realize the full potential of engineering with zinc! Fill out the form below to access our webinar and discover how zinc can help you achieve:</p><ul><li>Design freedom </li><li>Reduced assembly</li><li>Tighter tolerances</li><li>Faster cycles times</li><li>Reduced cost</li><li>Longer tool life</li><li>Enhanced surface finishing</li><li>And more!</li></ul><p></p>

Discover key design considerations and benefits of using zinc for your die casting projects in this expert-led webinar.

Zinc Die Casting Design Tips | Dynacast

Discover how to leverage zinc die casting to achieve design freedom, reduced costs, and enhanced performance with insights from our engineering team—access the webinar now! 

Designing in Zinc

<p>When considering a die casting conversion, it is essential to identify specific application factors that remain essential for the product's success. Additionally, selecting the optimal die casting alloy, whether it is ZN or AL, is crucial in ensuring the performance and cost-effectiveness of the final product. Cost reduction is one of the main reasons for die casting conversion, and understanding how the current part's cost will be significantly reduced through this process is crucial.</p><p>To learn more, register for our free on-demand webinar Converting to Die Casting in 12 Steps. In this webinar, Dave Haener and Don Marsh of Dynacast covered the following questions surrounding the benefits of converting to die casting: </p><ul><li>Why Should I Convert to Die Casting?</li><li>What Specific Application Factors Remain Essential?</li><li>How Do I Select the Optimal Die Casting Alloy: Zn vs Al?</li><li>How Will Current Part Costs Be Reduced?</li><li>How Can We Validate the Conversion</li><li>Where Can I See Examples of This Process?</li><li>And more! </li></ul><p><strong>Converting to Die Casting in 12 Steps</strong></p><p><strong>When: </strong>On-Demand</p><p><strong>Time:</strong> Watch Recording Now  </p><p><strong>Presenters:</strong> Dave Haener, Engineering Manager and Donald Marsh, Senior Business Development Manager - Dynacast</p><h2>Fill out the form to watch our free webinar on-demand.</h2>

Learn how to convert your process to die casting in 12 clear, effective steps to boost efficiency and product quality.

Die Casting in 12 Easy Steps | Dynacast

Discover the essential steps for converting to die casting, including alloy selection, cost reduction, and application factors, in our free on-demand webinar with Dynacast experts Dave Haener and Don Marsh. 

Converting to Die Casting in 12 Steps

<h1>Which production process is right for me?</h1><p>Precision metal components are achievable through many production processes besides die casting—screw machining, stamping, extrusion, and more. But the optimal production process for your component often comes down to efficiency and cost—which production process will add more value to your project?</p><p>Die casting is one of the oldest manufacturing techniques dating back to 1838. While the basic casting process hasn’t changed much, Dynacast's recent innovations in proprietary multi-slide technology and injected metal assembly capabilities allow manufacturers to create high-performing, net-shape components at scale.</p><p><strong>Download our free seminar where we discuss production alternatives and how they compare to die casting.</strong></p>

Compare die casting with alternatives like screw machining, stamping, and extrusion to determine the most efficient and cost-effective solution for your project. 

Comparing Casting Production Processes 

Explore the advantages and cost-efficiency of various production processes compared to die casting, including screw machining, stamping, and extrusion, in this insightful Dynacast webinar. 

Comparing Casting Production Processes

<p>We posted a blog about the cost of die cast tooling. We got such a great response from it we decided to host an hour-long webinar on the topic. Download the webinar and listen as our tooling experts discuss key elements that impact the cost of die cast tooling. They also cover how to get the most from your tooling and how to prolong tool life. </p><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p>

Explore the key factors influencing die cast tooling costs and discover expert tips on maximizing tool life in our comprehensive webinar. 

What Drives Tool Cost? 

Discover the key factors that impact the cost of die cast tooling and learn strategies to maximize tool life in this insightful hour-long webinar. 

What Drives Tool Cost?

<p>Download <strong>Voices from the Design World</strong> to see what your peers have to say about:</p><ul><li>The role technology has played in advancing design</li><li>Insights about emerging design engineering practices</li><li>Common frustrations with manufacturing partners, and the best ways to address them</li><li>Advice for keeping pace with change – and staying ahead</li></ul><p>And much more. Enter your details to get instant access.</p><p></p><p>Please fill out the form to access your copy of the white paper. </p>

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Explore key insights from the "Voices from the Design World" report on technology, design practices, and overcoming challenges with manufacturing partners. 

Voices from the Die Cast Design World | Dynacast White Paper

Explore insights from engineers on the evolving design engineering industry, including the impact of technology, emerging practices, and strategies for overcoming common challenges with manufacturing partners.

Voices from the Design World

<h1>Get your free white paper: Engineering Value: Balancing Design with Cost-Effective Production</h1><p>Get manufacturing costs down while staying true to design.</p><p>Design engineers who need to balance lower-cost parts with the integrity of their design have a new tool at their disposal – the practice of value engineering.</p><p>Get your free copy of <em>Engineering Value: Balancing Design with Cost-Effective Production</em> by simply entering your details below.</p><p><strong>Download your free copy of </strong><em><strong>Engineering Value: Balancing Design with Cost-Effective Production</strong></em><strong> to learn:</strong></p><ul><li>Where in the “product maturity curve” to introduce value engineering</li><li>6 key approaches to finding hidden value</li><li>Why it’s finally possible to achieve design-procurement balance</li><li>How you can immediately start applying value engineering</li></ul><p>And much more. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“There’s good news here, though. You can adopt a practice dedicated to identifying hidden costs that can be eliminated to make manufacturing less expensive—without compromising performance.”</p><h2>Download your copy to learn more.</h2>

Discover how value engineering in die casting helps design engineers reduce costs without compromising part integrity.

Balancing Design with Cost-Effective Production | Dynacast

Download "Engineering Value: Balancing Design with Cost-Effective Production" to learn how value engineering can reduce manufacturing costs without sacrificing design integrity.

Engineering Value

<h1>Get your free copy of “Which metal is right for me?”</h1><p>A visual metal reference guide. All in one place.</p><p>Your at-a-glance guide to key metals and their properties for die casting.</p><p>Get your free copy of “Which metal is right for me?” by simply entering your details below.</p><p>Download your free copy of “<strong>Which metal is right for me?”</strong> to learn about: </p><ul><li>The ideal applications for our most popular manufacturing materials</li><li>The key characteristics for specifying your project</li><li>Which manufacturing process a metal is suited for</li><li>More than a dozen alloys, and why you would specify them</li></ul><p>And it’s all in a simple, at-a-glance guide. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“The ‘castability’ of zinc, its wear resistance, and structural integrity make it perfect for the creation of the multi-faceted, highly complex shapes used in the automotive safety and electronics industry.”</em></p><h2>Download your copy to learn more.</h2><p></p>

Compare die casting metals and discover the best option for your product's strength and performance.

Which Metal is Right for Your Die Casting Project?

Explore key metal properties, ideal applications, and alloy options for die casting—all in one convenient, at-a-glance reference. 

Which Metal Is Right For Me?

<h1>Get your free copy of Creativity Without Compromise</h1><p>Pressure die casting with zinc-based alloys is one of the most efficient and versatile high-production methods used for the manufacturing of strong, accurate, complex, and intricately shaped metal components. </p><p>The process is carried out in an automatic machine suitable to withstand high pressure. The molten metal is pushed by a hydraulically actuated plunger into a two-piece steel die containing one or more cavities, each an exact inverse replica of the part or parts being produced. Because of the quick chill and rapid solidification that takes place when molten metal comes in contact with the relatively cool steel side, and because the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are generally superior to castings produced by other methods. </p><p>Zinc pressure die castings, for example, are stronger than sand cast 356-T6 aluminum, SAE 40 bronze, and class 30 cast iron. Also, pressure die cast components produced using the ZA alloys are stronger than pressure die cast aluminum 380 alloy. </p><h3>Please fill out the form to access your copy of the white paper.</h3>

Understand the high-pressure zinc die casting process and material options for strong, complex parts.

High-Pressure Zinc Die Casting Process Explained

This white paper explores the high-pressure zinc die casting process, highlighting its efficiency in producing strong, precise, and complex metal components compared to other casting methods. 

The High-Pressure Zinc Die Casting Process: Materials

<h1>Multi-Slide Hot Chamber Aluminum Machine</h1><p>Your biggest component production costs shouldn’t go to waste.</p><p>Download your free copy of our <strong>Multi-Slide Hot Chamber Aluminum Machine</strong> whitepaper to learn:</p><ul><li>Advantages and specifications of the Dynacast A3 Al SIS machine</li><li>Sustainability advantages</li><li>Typical shot material content</li><li>Part examples</li></ul><p>And much more. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“This advancement allows for the efficient production of aluminum parts by directly injecting molten metal into a permanent mold, overcoming previous limitations associated with cold chamber techniques.”</em></p><h3>Please fill out the form to access your copy of the white paper.</h3>

Learn how multi-slide hot chamber aluminum machines improve efficiency and precision in die casting.

Multi-Slide Hot Chamber Aluminum Machine Overview

Download our free white paper on the Multi-Slide Hot Chamber Aluminum Machine to explore the advantages, specifications, and sustainability benefits of the Dynacast A3 Al SIS machine. 

Multi-Slide Hot Chamber Aluminum Machine

<h1>Get your free copy of our Die Casting Design Guide</h1><p>Your biggest component production costs shouldn’t go to waste.</p><p>Yet that’s what many secondary operations will result—in fact, up to 80% of a component’s cost can be attributed to secondary operations that can be made more efficient—or eliminated altogether.</p><p>Get your copy of Die Casting Design Guide. Simply enter your details below.</p><p>Download your free copy of our <strong>Die Casting Design Guide</strong> to learn:</p><ul><li>How to reduce weight on components</li><li>Why wall thickness adds to cost</li><li>What the best draft angle is for inside vs. outside surfaces</li><li>The one critically important factor frequently overlooked by designers</li></ul><p>And much more. Enter your details to get instant access.</p><p>From the guide:</p><p><em>“Design for manufacturing (DFM) is a core methodology that ensures your die cast parts perform to specification and require the minimum of secondary operations. This is important when you consider that these operations can often represent as much as 80% of the component cost.”</em></p><h3>Please fill out the form to access your copy of the white paper. </h3>

Explore design tips and key considerations for creating high-quality, efficient die cast parts.

Your Complete Die Casting Design Guide

Download your free copy of our Die Casting Design Guide to learn how to reduce component costs by minimizing secondary operations and optimizing design for manufacturing. 

Die Casting Design Guide

<h1>Get your free copy of Creativity Without Compromise</h1><p>Faster timelines. Tighter tolerances. Lower costs. And did we mention faster timelines?</p><p>If you’re running into these challenging conditions on your projects, you might be forced to make sacrifices that ultimately compromise your design. Fortunately, there are some key steps you can take to ensure your vision becomes reality.</p><p>Get your copy of <em>Creativity Without Compromise</em>. Simply enter your details below.</p><p><strong>Download your free copy of </strong><em><strong>Creativity Without Compromise</strong></em><strong>. In this free guide, you’ll learn:</strong></p><ul><li>When to engage your manufacturing partner</li><li>Which DFM factors improve quality and lower costs</li><li>Why staying up-to-date with latest manufacturing techniques really matters</li><li>How looking at the big picture pays off, every time</li></ul><p>And that’s just the start. Enter your details to get instant access.</p><p><strong>From the guide:</strong></p><p>“When timings become strained, the root of the problem often lies in the early stages of the process. By working concurrently with the DFM team, you can ensure this crucial process flows smoothly, saving you valuable time (not to mention stress).”</p><h2>Download your copy to learn more.</h2>

See how precision die casting allows for creative, complex designs without sacrificing performance.

Creativity Without Compromise in Die Casting

Discover how to achieve faster timelines, tighter tolerances, and lower costs without compromising your design in the free guide, Creativity Without Compromise.

Creativity Without Compromise

<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>

Learn how die casting strategies help build resilient, reliable supply chains across industries.

Achieve Supply Chain Resilience with Die Casting

Download our free ebook Bulletproof Supply to discover key strategies for identifying and mitigating supply chain risks, ensuring your manufacturing projects stay on track.

Bulletproof Supply

<p>Mold release is a critical step in the die casting process, ensuring that precision metal components eject from the die effortlessly and free of defects.</p><h2>What is Mold Release?</h2><p>Mold release, also known as die spray or die lubricant, is a liquid that is applied to the steel mold before each shot of molten metal. The liquid evaporates when it comes into contact with the hot steel, leaving behind a thin, lubricated coating. This coating helps to prevent the metal from sticking to the mold, making it easier to eject.</p><h2>Why is Mold Release Important?</h2><p>Mold release is important for several reasons:</p><ul><li>It prevents the metal from sticking to the mold, which can cause defects in the finished part.</li><li>It helps the metal to flow more freely into the mold, resulting in a more accurate casting.</li><li>It reduces the amount of force required to eject the part from the mold, which can extend the life of the mold.</li><li>It can improve the cosmetic finish of the part.</li></ul><h2>Types of Mold Release</h2><p>There are many different types of mold release available, each with its own advantages and disadvantages. The type of mold release that is best for a particular application will depend on the type of metal being cast, the complexity of the part, and the desired finish.</p><ul><li>Water-based mold releases are the most common type. They are relatively inexpensive and easy to use. However, they can be less effective than other types of mold releases in preventing porosity.</li><li>Oil-based mold releases are more effective at preventing porosity than water-based mold releases. However, they are more expensive and can be more difficult to use.</li><li>Silicone mold releases are a good choice for parts that require a high-quality cosmetic finish. They are also effective at preventing porosity. However, they can be more expensive than other types of mold releases.</li></ul><h2>Mold Release Concerns</h2><p>There are two main concerns that customers typically have about mold release:</p><ul><li>Will mold release cause porosity?</li><li>Is mold release safe for medical and surgical applications?</li></ul><p>Porosity is a natural occurrence in the die casting process. However, the amount of porosity can be minimized by using the right type and amount of mold release. Dynacast works with customers to select the mold release that is best suited for their specific application.</p><p><br />Mold release can be safe for medical and surgical applications if it is properly applied and the part is properly cleaned after casting. Dynacast works with customers to ensure that their mold release is safe for their specific application.</p><h3>Dynacast is an ISO 13485 Certified Die Casting Manufacturer</h3><p>Dynacast is an ISO 13485 certified die casting manufacturer. This means that we have met the highest standards for quality and safety in the medical device industry. We use only the highest quality mold releases that are safe for medical and surgical applications.</p><h3>Contact Dynacast Today</h3><p>If you are looking for a die casting manufacturer that can provide you with the highest quality parts, contact Dynacast today. We have over 50 years of experience in the die casting industry and we have a team of experts who can help you with every step of the process.<br />We will work with you to select the right type of mold release for your application and we will ensure that it is applied correctly. We will also work with you to ensure that your part is properly cleaned after casting.</p>

Dynacast_Resources_Articles.png

Learn how mold release agents enhance die casting by preventing adhesion, improving part quality, and extending tool life in Dynacast's manufacturing processes.

Utilizing Mold Release in Die Casting Processes | Dynacast

See the essential role of mold release in the die casting process, detailing its types, benefits, and concerns to ensure defect-free and high-quality metal components.

Utilizing Mold Release During the Die Casting Process

<h1>Nickel-Free Coating for Die Castings</h1><p>Nearly every die cast material needs a coating for corrosion purposes. Typically for components that have cosmetic finishes, the best under layer for finishing is nickel. It has great adhesion properties and acts a barrier for the skin. To give you an idea, we would cast the component and then put a layer of nickel plating on the part to create a foundation for the cosmetic coating whatever that may be, satin chrome, PVD, etc. </p><p>With the continued rise of wearables and fitness trackers, the concern is when the coating would scratch off leaving a nickel to skin contact that creates challenges for die casters and suppliers in the consumer electronics industry. Buyers with sensitive skin can develop a rash from metal wearables containing nickel. Resulting in bad press for your business. With a 15% of Dynacast’s customers coming from consumer electronics, our Dynacast Singapore facility set out to find a solution.</p><h2>Highly-Cosmetic Nickel-Free Plating Options</h2><p>For years, to combat the allergic reaction caused by the nickel to skin contact, companies would make the components using MIM with stainless steel or machine it from aluminum or steel billet. Depending on the complexity of the component, die casting could be the more economical choice over MIM and it is almost always more cost-effective than machining from billet. We are talking about saving several dollars on part cost, which adds up very quickly with high volume runs. But businesses have to do what is necessary to prevent any sort of legal liability from an unhappy customer.</p><p><strong>Enter Dynacast Singapore with a great alternative. </strong>Nickel-free plating options for die castings that won’t leave consumers with awful skin rashes. This coating is used as the base layer before the cosmetic finish and it can be used on almost any material—though it works best on aluminum and zinc alloys. This gives design engineers the ability to design more freely.</p><p>The ability to design and make zinc and aluminum components for wearable market and offer them allergy free products has opened up a plethora of opportunities in the consumer electronics industry. These die casting options are lower in cost than their current components.</p><p><strong>This coating is also suitable for use in the virtual reality and medical device markets. With over 18 different color options, the possibilities for this coating are endless.</strong></p>

Explore Dynacast's nickel-free coating options for die cast parts, offering corrosion resistance and aesthetic appeal without nickel-related sensitivities.

Nickel-Free Coating Solutions for Die Castings | Dynacast

A nickel-free plating option for die castings that provides a cost-effective, allergy-safe solution for consumer electronics, medical devices, and other applications, offering enhanced design flexibility and a variety of cosmetic finishes. 

Nickel-Free Coating for Die Castings

<p>Aluminum is one of the most commonly used materials in die casting. It’s lightweight, strong, rigid, and can withstand high temperatures, which makes it common across many industries. Some other qualities of aluminum include:</p><ul><li>Good stiffness and strength-to-weight ratio</li><li>Corrosion resistance</li><li>Heat dissipating</li><li>Fully recyclable</li><li>Ideal for harsh environments</li><li>Excellent EMI shielding properties</li><li>Excellent thermal conductivity</li><li>Good finishing characteristics</li><li>Good machining characteristics</li></ul><h2><strong>Aluminum Alloys</strong></h2><p>At Dynacast, the aluminum alloys that are most commonly used in North America are A380, 383 and 413 with their equivalent Asian and European alloys being used in other regions. However, a number of other alloys are available depending on customer requirements and product design needs. Unlike primary aluminum alloys that have to be mined and extracted from ore, these secondary alloys are derived from primary aluminum scrap, which means they are more environmentally friendly. Dynacast has aluminum plants all over the world, which means your aluminum parts can be manufactured in a location that’s best for you. </p><p>Below are two industry examples of how aluminum can be used:</p><h3>Automotive</h3><p>Unlike conventional hot-chamber die casting, which utilizes a two-part tool, multi-slide employs four perpendicular slides in the tool, allowing for the creation of intricate and precise castings. This technology provides design freedom, enabling the production of complex geometries with unmatched accuracy.</p><h3><strong>Handheld Devices</strong></h3><p>Aluminum die cast shields and housings give EMI shielding, rigidity, and durability with minimal additional weight for handheld devices. This becomes an important quality when emission and interference suppression requirements are high.</p><p></p>

Explore the benefits of aluminum die casting—lightweight, strong, and corrosion-resistant. Discover Dynacast's expertise in aluminum components.

Aluminum Die Casting Spotlight | Dynacast Article

Aluminum die has benefits and applications in various industries. Key applications include automotive and handheld devices.

Aluminum Die Casting Spotlight

<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><h1>What is Injected Metal Assembly?</h1><p><em>There are many different methods of joining metal and other materials, and depending on your industry, there certain considerations that determine the most effective method of assembly. If you’re currently crimping, soldering, staking, or welding components together, injected metal assembly (IMA) could be a more efficient and reliable option for you.</em><br />What is injected metal assembly?</p><p>The IMA process is a type of Insert Molding that uses a molten zinc alloy to join similar or dissimilar components together and create a singular assembled part that is strong, flash-free, and repeatable. With production rates up to 1,000 parts an hour, IMA adhesion ensures consistent higher quality parts while keeping manufacturing costs low.</p><p><strong>The uneven heating and cooling of the welding process produces brittle joints that are vulnerable to stress. As a result, their fatigue strength is far less than that of components joined by IMA.</strong></p><h3>How does IMA work?</h3><p>First, the components that need to be assembled are placed into the machine in a custom designed casting tool. These custom tools are able to accommodate components of various shapes, sizes, and materials.</p><p>Next, the tool closes and precisely aligns to holds the components in their precise position while the molten alloy is injected into the cavity at the intersection of the components. The alloy—usually zinc for its high strength, dimensional stability, and load-bearing characteristics—solidifies in a fraction of a second and produces a strong, permanent lock between the components. Finally, the tool opens and the assembled part is ejected from the die. The ejected component is flash-free, requires no secondary operations, and is stronger than conventionally joined metal components.</p><p><em>When the zinc alloy is injected, it fills the cavities in the custom tool and hardens to create a permanent bond between the components.</em></p><p>In addition to being high in strength and stability, zinc alloys are predictable in their flow and shrinkage characteristics, enabling our designers to calculate with high accuracy the final dimension of the injected metal joint. This allows for exacting tight tolerances to improve the overall functionality of the part.</p><h3>What is the required volume for the IMA process to be viable?</h3><p>Dynacast is capable of running varied volumes, down to 5,000 pieces a year if need be and up to 3 to 4 million parts per year with the help of automation and robotics. The volume of production is largely dependent upon the needs of the customer.</p><h3>When joining metal and a material like plastic, how do you keep the plastic from melting when it comes in contact with the injected molten metal?</h3><p>With IMA, we are able to hold the die closed for up to a whole second, depending on the fragility of the plastic, and allow the heat to dissipate in the water-cooled tool. In addition to this cooling process, the low melting point of injected metal prevents thermal degradation of the parent materials.</p><h3>Can you prototype an IMA part?</h3><p>Yes. While we cannot create a complete part before production begins, Dynacast can build simple “soft tooling” and create part-specific cavity blocks to insert into the tooling for a low production concept. Dynacast also offers a pull-ahead system where we build the tool to a certain point, and if parts produced are accepted by the customer, we complete the tool.</p><h3>How does IMA reduce cost?</h3><p>IMA reduces cost by cutting production time and eliminating the need for secondary operations. While processes like welding, soldering, and crimping are often very labor intensive, IMA has the potential to be fully automated. When part is ejected, flash-free and permanently bonded, it is ready for use.</p><h3>What are major markets served by the IMA process?</h3><p>The IMA process serves virtually any industry and any application. Automotive, telecommunications, electronic components, hardware and appliances, industrial controls, and military industries often utilize parts crafted by the IMA process.</p><p><strong>Would you like to learn more about the IMA process and practical applications? Fill out the form to download our free webinar!</strong></p>

Discover Dynacast's IMA process—a cost-effective method using molten zinc to join components, enhancing strength and reducing assembly steps.

What Is Injected Metal Assembly? | Dynacast Article

Injected Metal Assembly (IMA) is a high-efficiency manufacturing process that uses molten zinc alloy to permanently join metal components with precision, creating strong, flash-free parts with reduced production costs and enhanced reliability compared to traditional methods like welding and soldering.

What is Injected Metal Assembly?

<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>

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

<h1>Dynacast Surface Coatings: A Comprehensive Guide</h1><p>Is your part in need of a surface coating but uncertainty about the best option prevails? Dynacast offers a diverse range of approximately thirty coatings, from chrome to electroless nickel and beyond. This comprehensive guide explores several key coating types, their characteristics, and suitable applications.</p><p>While this blog covers many options, Dynacast constantly introduces new surface coating solutions based on customer demands. If you require a coating not listed here, please contact our team.</p><p>For detailed information on specific surface finishing options, consult with one of our design engineers.</p><h2>Chrome vs. Chromate</h2><p>Before looking into specific coatings, it's essential to differentiate between chrome and chromate. Chrome, derived from chromium, is an electroplated finish often associated with a shiny, metallic appearance, as seen on automobiles. Chromate, conversely, is a corrosion-resistant conversion finish rather than an additive coating. Dynacast provides numerous options for both chrome and chromate finishes.</p><h3>Chrome Plating</h3><p><strong>Bright Chrome:</strong>&nbsp;This mirror-like finish is familiar from automobiles, toys, and furniture. It offers corrosion protection, good wear life, and aesthetic appeal.</p><p><strong>Satin Chrome:</strong>&nbsp;Similar to bright chrome but with a duller finish. Both finishes involve rack plating with layers of copper, nickel, and chrome.</p><h3>Chromate with Zinc</h3><p>Zinc coatings are soft, decorative, and corrosion-resistant, protecting the base metal through sacrificial corrosion. Chromate application enhances corrosion protection.</p><ul><li><strong>Clear Chromate with Zinc:</strong>&nbsp;Exhibits a slightly iridescent blue hue.</li><li><strong>Yellow Chromate with Zinc:</strong>&nbsp;Imparts a yellow color to the finished part.</li><li><strong>Black Chromate with Zinc:</strong>&nbsp;Provides a black finish.</li></ul><h3>Chromate without Zinc</h3><p>Black chromate without zinc is an inexpensive type of chromate. It’s typically used for parts that do not require a high amount of corrosion resistance. The coating goes directly onto a zinc die cast part. Yellow chromate parts are chemically milled and then chromated. This gives the part a dull finish. Both of these coating options are very thin and contribute no measureable thickness to the overall coating.</p><h3>Additional Chromates</h3><ul><li><strong>Olive Drab Chromate:</strong>&nbsp;Features a dark green finish and withstands 150 hours to white corrosion.</li><li><strong>Trivalent Chromate:</strong>&nbsp;Offers similar properties to traditional chromate without containing hexavalent chromium. Environmentally friendly with a bright blue color, exceeding automotive specifications.</li></ul><h3>Nickel Plating</h3><p>Nickel plating, characterized by a yellowish-white color and hard reflective finish, excels in wear resistance, solderability, and dimensional repeatability. Typically applied over copper on die castings, it also serves as a base layer for chrome plating.</p><ul><li><strong>Bright Nickel:&nbsp;</strong>The most common type but exercise caution with cold-forming due to potential ductility compromise.</li><li><strong>Watt's Nickel:&nbsp;</strong>Offers a satin finish and improved ductility, suitable for components requiring cold-forming.</li></ul><h3>Electroless Nickel</h3><p>Unlike electroplating, electroless nickel deposition does not require an electric current. This process yields exceptionally uniform coating thickness. It is widely used for its corrosion, wear, and abrasion resistance, along with ductility, lubricity, solderability, and hardness.</p><ul><li><strong>Low, Mid, and High Phosphorus:&nbsp;</strong>Varying phosphorus content influences properties.</li><li><strong>Black and Dark Blue Electroless Nickel:&nbsp;</strong>Primarily for decorative purposes.</li></ul><h3>Tin Plating</h3><p>Tin plating is ideal for components undergoing soldering during assembly. It offers excellent ductility, high solderability, and good surface coverage.</p><ul><li><strong>Matte Tin: Typically exhibits better solderability than bright tin.</strong></li><li><strong>Bright Tin: More commonly specified due to its superior appearance.</strong></li></ul><h3>Cobalt-Tin</h3><p>Resembling chrome in appearance and application, cobalt-tin involves copper/nickel plating followed by a cobalt-tin flash for a chrome-like finish. Known for its hardness and durability.</p><h3>Silver Plating</h3><p>Silver is valued for its low cost, despite tarnishing susceptibility to sulfur. It is primarily chosen for decorative, electrical conductivity, or thermal conductivity purposes. Offers high electrical and thermal conductivity, solderability, malleability, and ductility.</p><h3>Gold Plating</h3><p>Frequently used in electronics due to its low contact resistance, solderability, and wire bonding capabilities. Alloying with cobalt enhances hardness and wear characteristics. Gold plating is available in four types: pure gold, hard gold, electroless gold, and immersion gold. Refer to the surface finishes page for details.</p><h3>Cadmium Plating</h3><p>Offers exceptional corrosion protection, approximately double that of zinc. Commonly used in aerospace, marine, and saltwater environments.</p><h3>Brass Plating</h3><p>Primarily used for decorative purposes, brass plating can be applied in bright or satin finishes and oxidized for an antique look. A lacquer topcoat can enhance coating longevity.</p><h3>Chem Film</h3><p>Chem film, also known as a conversion coating, is specifically designed for aluminum die castings. The coating's color can range from dark golden brown to light yellow, depending on various factors. Importantly, chem film does not alter the part's dimensions. There are two primary types of chem film: Class 1A and Class III, which are detailed on Dynacast's surface finishing page.</p><h3>Black E-Coat</h3><p>Black e-coat is a paint coating electrically applied to enhance a part's appearance and protect its surface.</p><h3>Anodizing</h3><p>Anodizing creates a non-conductive, protective coating that seals the part. Commonly used types include clear and black anodize. The final color is influenced by the die casting alloy, with aluminum exhibiting minimal color change. Anodizing allows for various color dyeing options, with black, blue, and red being the most popular. Two classes exist: Class 1, the natural color without dye, and Class 2, dyed to a specified color.</p><h3>Polyurethane Paint</h3><p>Renowned for its exceptional durability, polyurethane paint is often recommended for outdoor or exposed parts. It can be applied in smooth or textured finishes and typically air-dries, though baking accelerates the process.</p><h3>Powder Coating</h3><p>Powder coating surpasses standard wet paints in terms of thickness uniformity and color consistency. The coating process involves curing at elevated temperatures, resulting in exceptionally tough finishes. Beyond its high hardness, powder coating is visually appealing, effectively conceals minor surface flaws, and delivers a durable, high-gloss appearance. Additionally, it is environmentally friendly, posing no air quality or hazardous waste concerns.</p><h3>Black Oxide</h3><p>Black oxide provides a protective, corrosion-resistant finish. While commonly associated with firearms, it also finds applications in spark plugs, furniture brackets, and mower blades. The black finish is chip-resistant and acts as an absorbent for oils or wax. Its economic nature, coupled with its ability to extend a part's service life and performance, makes black oxide a valuable coating option.</p>

Explore Dynacast’s surface finishing options, including chrome and chromate coatings, to enhance corrosion resistance and aesthetics of die cast components.

Surface Finishing Options for Die Cast Parts | Dynacast

Multi-slide die casting is a sustainable manufacturing process that offers environmental benefits.