Aluminum Sand Cast Parts are sometimes a better choice than Aluminum Die Casting Parts

If you want less than 2,000 aluminum parts in your product life cycle, sometimes a part produced by the aluminum sand casting is a better choice for you.

Here are my calculations:

Aluminum Sand Casting Parts
Typical Tooling Cost: $500 – $1500
Typical Part Cost: $12 – $15 each
Cost for 1000 parts: $13,500
Cost for 2000 parts: $25,500

Aluminum Die Casting Parts
Typical Tooling Cost: $10,000 – $12,000
Typical Part Cost: $2.50 – $3.50 each
Cost for 1000 parts: $14,500
Cost for 2000 parts: $17,000

As you can see, the cost is less for an aluminum sand cast part, if you will buy less than 2000 parts. If you feel your product life is more than 2000 parts, you should consider buying aluminum die casting parts.

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Kinetic Die Casting Company Update

Kinetic Die Casting Company hired:
Delmas Pattee – Sales – Please call and welcome Delmas to Kinetic Die Casting Company.

Kinetic Die Casting Company Advertising Offer
Our blog (www.kineticdiecasting.com/kdc/) is full of general die casting and specific die casting information. We write every week about the die casting process and our ways of dealing with the typical die casting problems.

200 to 500 people visit our blog every day, mostly engineers and die casting part users. There is a StatPress counter in the right side for you to see how many visitors to the blog that day.

My special Internet Advertising offer is this:
Send me an article about your company, product or service and I will post it on my blog.

Here are the conditions:

1. The article must be an original article, not one used elsewhere.
2. The article must be more than 100 words and less than 1,000 words in length.
3. The article should be about your company, product or service.
4. Do not send an article about anything offensive please.
5. The article can/may contain pictures.
6. The article can/may contain two links to your website.
7. I choose which articles to use or not use on my blog.
8. I choose when the article posts on my blog
9. I choose how long it remains on the first page of my blog.
10. If you are a competitor, I may still consider your article if it is “tasteful” and not negative.

Send your article to sales@kineticdc.com

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Contact Kinetic Die Casting Company 818-982-9200 if you would like us to die cast your new product.

Cinema Products Corporation
3211 South La Cienega Boulevard
Los Angeles California 90016

Produced the waist mounted camera harness for the movie industry. We were contacted by Cinema Products to look at a revolutionary new aluminum locking mechanism for their product. There were 10 items that created the locking mechanism consisting of Pivots, Pawls and Locks for the left and right side of the harness. We made aluminum die casting tooling for them the cost was about $50,000.

The weight of the 10 parts was very light because of their material choice, but they ran into some issues that made 380 aluminum a poor choice for the alloy. Units were failing in the field. We discovered it was because of the limited impact strength of 380 aluminum of 3 foot pounds. We suggested another die casting material, #3 zinc alloy, which has an impact strength greater than 40 foot pounds.

Cinema Products believed they were stuck at an impasse to pay another $50,000 for zinc die casting tooling. Kinetic Die Casting was able to produce zinc parts using the aluminum die casting tooling, saving them several thousands of dollars.

If you had a die casting part failure in the past, contact Kinetic Die Casting Company for assistance 818-982-9200.

Kinetic Die Casting Company has helped many die casting customers develop new products.

There are many factors singular to the die casting process that are needed to be considered such as product strengths, draft angles, gate areas, material types, material flow, slide features, undercuts, wall thicknesses and material weights.

Kinetic Die Casting Company makes die casting parts in zinc.

Kinetic Die Casting in the past specialized in making Aluminum Die Casting Parts, but over the past five years, we have been making more die casting parts in ZINC ALLOYs. We have a web page dedicated to zinc die casting alloys

(http://www.kineticdiecasting.com/zinc.html)

Take a few moments to review the differences in the various zinc die casting alloys.

For 18 pages of Alloy Data, more information than most people ever need, review this PDF.

( http://www.kineticdiecasting.com/Alloy_Data.pdf )

Contact us 818-982-9200 if you have technical questions regarding die casting materials. We will be happy to help you decide which die casting material is best for your product or application.

Kinetic Die Casting has implemented lean manufacturing for continuous improvement for quite a long time.

I just wanted to remind our customers that fast delivery and great quality is our number one goal to serve our customers.

As a part of our continuous improvements, if you want a service that we do not provide, please contact me 818-982-9200.

Our backlog of work continues to grow. We will be happy to help you with any new project. Contact me if you need prices.

Kinetic Die Casting Company current delivery time for raw castings is
……… less than six 6 weeks.

Contact Kinetic Die Casting Company 818-982-9200 if you have a difficult product to produce. We will be able to make parts for you when others fail. Send us your die casting tooling and we will make your parts for you.

A customer of ours, in the early 1990’s, contacted Kinetic Die Casting Company, to send us their die casting tooling so we could produce an aluminum die cast enclosure housing for them. This company, Monitor Dynamics Incorporated (MDI), produced a security card reader system used in government buildings. MDI was well known for their high quality security systems. MDI demanded high quality products from their suppliers.

This aluminum die casting part had transformed many times from its inception. It started out as a steel box that was welded together. The design was simple, ¼ inch plates welded together in a box shape with a slot to slide electronic cards through and an area for a keypad. The next change was to make aluminum sand castings in a similar design. Later, the delivery and quantity requirements for the programs required MDI to purchase die casting tooling and die casting parts from a competitor of ours.

Unfortunately, our competitor did not realize the important differences between aluminum sand casting parts and aluminum die casting parts. The part design was poorly planned in the following ways:

• The draft on the interior walls was not properly created, the parts has several drag marks and stuck too easily in the tool.
• The tooling die not include a mold base, it consisted of inserts only. This kept the customer captive to the poor quality die casting company, our competitor.
• The wall thicknesses of 1/4” or more, “for higher strength”. Greater wall thicknesses in die casting parts for greater strength is a misconception.

Here is how I helped MDI get good quality parts. First, I had my toolmaker fix the internal draft angle problems so the aluminum housing parts would no longer stick in the die casting tool. Secondly, I mounted the inserts into one of our many available mold bases so we could make good quality die casting production parts.

Then finally, we fought the production process to make good parts in spite of the problems and complications from the ¼” or greater wall thicknesses. There were many complications, such as, several sink marks or surface porosity from the metal wicking from thinner areas of the casting to the thicker areas. The casting would deform easily in the cooling process. The internal porosity from the thicker sections would also cause the paint and powder coating to bubble.

MDI was very pleased with the results we provided them. Their purchasing manager sent me a letter of appreciation. MDI is now known as Ameritron, Incorporated. You can read a copy of the letter of appreciation from the purchasing manager here..

“In the 12 years, Kinetic Die Casting has been an excellent supplier providing good pricing, excellent product and on time delivery. If you have a need for die casting products I would highly recommend Kinetic Die Casting”

……. Read letter HERE