Kinetic Die Casting Blog

What are Diecast Parts and Why Use Them? Diecast parts are the collective end result of a tedious process that is governed by strict principles of metallic and hydraulic science and powered by technology. This process is known all around the world today as diecasting, an age-old method that has lasted for over a century now. The process involves the injection of molten metal into steel molds or dies under high pressure. There are a variety of metals that can be used for the process; whatever the choice of the manufacturer is, that particular metal is held under pressure until, finally, it hardens into a metal part carrying a net shape.

Today, the diecasting process enjoys a highly marketable popularity in the metalworking industry, thanks primarily to the many advantages it offers to manufacturers and consumers alike. If you haven’t been keen on going for diecast parts, it’s about time you switch and leave your current choice of casting method for good.

The diecasting process is first and foremost a versatile process that provides manufacturers and consumers with a much broader range of choices in terms of shapes, sizes, and components more than any other manufacturing technique for metalwork nowadays. Die cast parts can come out in a variety of physical appearance and with accurate dimensional tolerances, exact measurement specifications, and different finishing options – from textural feel to visual form. What’s more, diecast parts are economical to make. They don’t need much assistance from machines and tools before, during, and after production. Both manufacturers and consumers can save hundreds of dollars when they go for diecasting company parts.

The History of Metals and Man in the Die Casting Process. To understand the die casting process is to understand the history of metallurgy and to peruse the history of man. Man has been shaping metal since antiquity. We fashioned our tools, weapons, and implements from the metals we found in the earth. The first metal we used was gold, then copper. Gold exists in its natural state and did not require much processing, but copper had to be smelted. This was the start of a crude metalworking industry.

The manufacturing of die cast parts in modern times is a far cry from those first attempts of civilization. Now it is not an outdoor bonfire that we use, but a high tech die casting machine inside a die casting company to melt and mold our metals. Aside from copper, we have discovered more useful metals like aluminum, zinc, tin, brass, magnesium, and lead.

The parts we manufacture out of metal are not anymore crude knives and arrowheads, but precision parts for modern industries like telecommunications and automobiles, mobile phones, fiber optics, computers and laptops, children’s toys and collectibles such as die cast model cars and airplanes.

The process we use is high pressure injection molding and a four step procedure involving lubricants and shots and ejector pins, or a heated-manifold what they call direct-injection die casting procedure which is a less complicated procedure than the first one, no matter how it sounds.

The metal parts that we manufacture nowadays are various things like mobile phone antennas, electronic connectors, industrial housings and fittings, bicycle pedals, sprockets, gas knobs and valves, handles and lids, door hinges, fasteners, doorknobs and zippers.

Die Casting Molds. Aluminum die casting is the method for manufacturers to fulfill orders for large quantities of small to medium sized metal parts. This versatile process has been placed among the highest volume products made by the metalwork industry.

The process of die casting starts off with molten metal. This molten metal is then forced into the Die Casting Molds in a high pressure environment. After which, they are then machined into dies. This process results in the metal parts to be consistent in their dimensions, with high quality and good detail. For most of the time, die casting makes use of non ferrous metals such as tin, aluminum, zinc and copper among others but ferrous metals can also be used in this process. However, harder and stronger metals such as steel and iron cannot be used in this process; instead they are used to make Die Casting Molds.

These die cast molds come in a number of different shapes and sizes. Some can be made as single cavity molds which can make one part for every cycle or multiple cavity molds which can make several parts in a single cycle. Their shape and design would determine the cost of these molds; the more complex the design then the higher the cost of the mold would be. They can be very expensive, ranging from hundreds of dollars to thousands of dollars per mold.

When the molten metal is placed into the Die Casting Mold, they are then placed in either a hot chambered machine or cold chambered machine to complete the process.

Die Casting: Some Questions Answered. What is a die? A die is also sometimes called a mold, is tooling to produce die cast parts. A die cast tool is a metal block tool used to make die casting parts. What is die casting? Die casting is the process by which the metalworking industry manufacture and fabricate metal parts; it is a way of forming metal objects by injecting molten metal into a die cast tool or a die cast mold under high pressure. Many copies can be made, over 100,000 parts from each die casting tool, thereby making it an economical process. It is ideal for mass production.

What metal parts can be fabricated using the die casting process? In the automobile industry, this is how cylinder heads and engine blocks are made. Tiny sewing machine parts can also be made in this way, as well as parts for medical devices and refrigeration units, for it is a precision process that creates a precision product. The finished product of a die cast mold has good surface finish, good detail even if it has a complicated design, and it is sharply outlined.

Tooling for die casting is made of steel. What are the kinds of metals used in die casting parts? The metals have to have a low melting point, and they are usually non ferrous (meaning they do not contain iron). Examples of these kinds of metal and metal alloys are zinc alloy, magnesium, tin and lead, brass, aluminum alloy, and copper.

What are the characteristics of a die cast metal? Die casting parts using the prescribed metals make them tough, well-built, heat resistant, stable and molded with precise dimensions. There are various finishing techniques available to metal parts that are made using the die casting process, your choice of smooth or textured, plated or finished some other way.

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