Die Casting Porosity and Its Causes. Die Casting porosity is one of the most common defects in the die casting manufacturing industry. What is die casting porosity? Die Casting porosity is a kind of die casting factory imperfection in which …
Continue reading
Category Archives: Diecasting Process
Calculating Die Casting Part Prices
Kinetic Die Casting Company describes the information needed to provide aluminum die casting part prices. We will detail the most common variables needed to provide pricing for die casting parts.
Here is a list of variables and following the list are the details of those variables we need to give prices. We sell four things to our die casting part customers:
1. Materials
2. Labor
3. Processes
4. Overhead
- Falling in the Materials category:
- Die Casting Part Weight – The die casting part weight determines what the variable multiplied by the material cost per pound costs. The part weight is also a factor of how many parts can be produced in an hour.
- Die Casting Part Material or Alloy – Every die casting material alloy has a different cost every pound that is used to make the die casting parts. Some customers request a different alloy to make the parts which changes the material cost in the part. Some alloys also operate faster than other die casting alloys, reducing overhead cost.
- Packaging costs and shipping costs also falls in this category
- Falling in the Labor category:
- Multiple Cavity Die Casting Tooling – If we produce more parts each hour with multiple cavities, it will reduce the die casting part cost.
- Tooling type and Setup Costs – Time during our die setup is considered “downtime” because we are not making parts. The downtime adds cost to the die casting part price. Differing tool types take longer to setup than others. Die casting cavity inserts cost the most to setup. The least cost tool to setup is the DME Unit Die.
- Die Casting Trim Tooling – Is there a trim die available? A trim die can reduce the die casting part prices as much as 15%.
- Other trimming cost – Hand sanding or grinding the parting line flash is labor intensive and adds cost to the die casting part price. Are there machining operations necessary to make good quality parts? These costs add to the part price. Will be use vibratory deburr to smooth sharp edges or to prepare the part for paint? This adds a cost to the parts.
Worn Die Casting Tools – Older dies produce much more flash than new dies and adds to the part price the flash removal.
- Falling in the Processes category:
- Inspection Processes – Processes like x-ray and penetrant inspection add cost to the parts. A FAIR (First Article Inspection Report) adds a cost to the overall production.
- Surface Treatments – Processes such as Alodine (Chem-Film) or Painting or Powder Coating or Plating all add cost to the die casting part price.
- Falling in the Overhead category:
- Delivery Quantity and Annual Quantity – The requested shipment quantity influences the part cost because the die casting mold setup cost is distributed in the delivery quantity and annual quantity.
- Overhead in a small amount is distributed throughout all the parts we make include utilities and Insurance – Rent – Etc.
Die Casting Part Prices
die casting part prices
(https://www.kineticdiecasting.com/replyform.html)
Calculating Die Casting Part Prices
|
Kinetic Die Casting Company, Inc. 6918 Beck Avenue, North Hollywood, California USA 91605 E-mail sales@kineticdiecasting.com (818) 982-9200 California Die Castings – Die Casting Photos – Technical FAQ – Die Casting Prices – Kinetic Die Casting Company What is Die Casting ? – Why Use Die Casting – Kinetic Abilities – Die Casting Offshore ? – Sand casting prices and die castings – Die Casting Tooling – Kinetic Newsletter |
If you no longer wish to receive these emails, you may unsubscribe here.
Posted in Blogger, Business, Die Casting Parts, Diecasting Process, Employee, newsletter
Tagged #diecasting, #kineticdc, Manufacturing
Leave a comment
Kinetic Die Casting Compares Die Castings To Other Production Processes
Die casting – A manufacturing process in which molten metal is injected, under pressure, into a hardened steel die or also called mold. Dies are often water-cooled. Dies are then opened, and the die castings are ejected (many times thousands of parts each day, sometimes only a few hundred). Once the tooling is paid for, die casting is a very inexpensive aluminum part manufacturing process. We can make over 2000 die casting parts a day.
Compare Die Casting Process
Die Casting Part Prices
Forgings – Compared with forgings, die casting can be more complex in shape and have shapes not forgeable, can have thinner sections, be held to closer dimensions, and have coring not feasible in forging.
Plastic Injection moldings – Compared with plastic injection moldings, die casting are stronger, stiffer, more stable dimensionally, more heat resistant, and are far superior to plastics on a properties/ $ cost basis. They help prevent radio frequency and electromagnetic emissions. For chrome plating, die castings are much superior to plastics. Die castings have a high degree permanence under load compared to plastics, are completely resistant to ultra-violet rays, weathering, and stress-cracking in the presence of various reagents. Manufacturing cycles for producing die castings are much faster than for injection moldings.
Extrusions – Compared to extrusions, die casting can be produced faster and more net shape. Features and depressions on the sides, tops and bottoms can be created in one operation. There is less waste using die casting than extrusion. Holes can be cast in place to save additional machining cost.
Stampings – Compared with steel stampings, one die casting can often replace several parts. Die casting frequently require fewer assembly operations, can be held within closer dimensional limits, can have almost any desired variation in section thickness, involve less waste in scrap, and are producible in more complex shapes. Die castings can be made in many shapes not producible in stamped form.
Screw Machine Parts – Compared with screw machine products, die castings are produced more rapidly, involve much less waste in scrap, can be made into shapes that are difficult or impossible to produce from bar or tubular stock, and may require fewer operations.
Sand castings – Compared with sand castings, die castings require much less machining, can be made with thinner walls, can have all or nearly all holes cored to size, can be held within much closer dimensional limits, and are produced more rapidly in dies which make thousands of die castings without replacement. Die castings do not require new cores for each casting, are easily provided with inserts die cast in place, have smoother surfaces and involve much less labor cost per casting.
Permanent mold castings – Compared with permanent mold castings, die castings can be made to closer dimensional limits and with thinner sections and holes can be cored to near net shape. Die castings are produced at higher rates with less manual labor, have smoother surfaces, and usually cost less per die casting.
Die Castings Compared to other Manufacturing Processes
|
Kinetic Die Casting Company, Inc. 6918 Beck Avenue, North Hollywood, California USA 91605 E-mail sales@kineticdiecasting.com (818) 982-9200 California Die Castings – Die Casting Photos – Technical FAQ – Die Casting Prices – Kinetic Die Casting Company What is Die Casting ? – Why Use Die Casting – Kinetic Abilities – Die Casting Offshore ? – Sand casting prices and die castings – Die Casting Tooling – Kinetic Newsletter |
If you no longer wish to receive these emails, you may unsubscribe here.
Posted in Blogger, Die Casting Parts, Diecasting Process, newsletter
Tagged #diecasting, Manufacturing
Leave a comment
Why Draft Angle Is Important for Die Casting Manufacturers
A small die casting design detail requires attention for its outsized impact on quality, cost, and production efficiency: the draft angle in die casting parts.
Die casting draft angle refers to the slight taper applied to vertical surfaces of a die cast part, allowing it to be released cleanly from the steel die after solidification. While the concept has been standard practice for decades, industry experts say misunderstandings about draft angle continue to cause delays, redesigns, and unexpected tooling costs—particularly as demand rises for complex aluminum enclosures and precision components.
“Draft angle is not optional in die casting parts,” said one tooling engineer at a California aluminum die casting facility. “If the walls are straight with no taper, the part will stick in the die. That leads to damaged castings, excessive wear on tooling, and production downtime.”
Why Die Casting Part Draft Angle Matters
A380 Box
In aluminum die casting, molten metal is injected into hardened steel dies under high pressure. As the aluminum cools, it shrinks slightly and grips the die surfaces. Draft angle creates clearance, allowing ejector pins to push the part out smoothly without distortion.
Die Casting Industry guidelines typically recommend 1 to 2 degrees of draft per side, with two degrees considered a safe standard for most aluminum castings. However, the exact requirement can vary depending on wall thickness, surface finish, alloy selection, and whether slides or lifters are used in the tool.
Despite its importance, draft angle is often overlooked during early design stages, especially when parts are designed by engineers unfamiliar with die casting or adapted from machined or plastic components.
Die Casting Part Prices
Impact on Die Casting Part Dimensions
Draft angle directly affects part geometry. For box-shaped enclosures—common in electronics, automotive, and industrial applications—the internal and external dimensions change from top to bottom. A box that measures four inches wide at the opening may be significantly smaller at the bottom once draft is applied.
“If a customer designs a box to fit electronics tightly without accounting for draft, the components may not fit,” explained a die casting project manager. “That usually means redesigning the part or modifying the tool, both of which add time and cost.”
Cost and Quality Implications
From a business perspective, proper draft angle improves more than manufacturability. Adequate draft reduces tool maintenance, increases die life, improves surface finish, and stabilizes production rates. Conversely, insufficient draft can lead to scrap, flashing, or galling inside the die.
As manufacturers face tighter margins and shorter lead times, avoiding preventable tooling changes has become increasingly important.
A Growing Focus on Design for Manufacturing (DFM)
The renewed focus on draft angle reflects a broader industry trend toward die casting design for manufacturing (DFM). Many die casting companies now review customer designs early in the quoting process, flagging draft issues before tooling begins.
“With today’s complex parts and higher expectations, you can’t afford to treat draft as an afterthought,” said the engineer. “It has to be designed in from the start.”
As die casting continues to serve industries ranging from aerospace companies, electric vehicles to renewable energy, understanding fundamentals like draft angle in die casting parts remains essential. Sometimes, the smallest angles make the biggest difference.
|
Kinetic Die Casting Company, Inc. 6918 Beck Avenue, North Hollywood, California USA 91605 E-mail sales@kineticdiecasting.com (818) 982-9200 California Die Castings – Die Casting Photos – Technical FAQ – Die Casting Prices – Kinetic Die Casting Company What is Die Casting ? – Why Use Die Casting – Kinetic Abilities – Die Casting Offshore ? – Sand casting prices and die castings – Die Casting Tooling – Kinetic Newsletter |
If you no longer wish to receive these emails, you may unsubscribe here.
Key Differences Between #3 and #5 Zinc Die Casting Alloys
In zinc die casting, two alloys dominate: Zinc Alloy #3 (commonly known as Zamak 3) and Zinc Alloy #5 (Zamak 5). These high-purity zinc-based materials, primarily composed of zinc with about 4% aluminum and small amounts of magnesium, are essential for producing precise, complex parts in industries ranging from automotive to consumer electronics. While both offer excellent castability, low melting points, and superior surface finishes, their differences in composition drive distinct performance characteristics.
#3 Zinc Alloy vs #5 Zinc Alloy
Die Casting Part Prices
The primary distinction lies in copper content. Zinc Alloy #3 has minimal copper (typically less than 0.03%), making it the most widely used alloy in North America—accounting for over 70% of zinc die castings. Zinc Alloy #5, prevalent in Europe, incorporates 0.7-1.1% copper, boosting certain mechanical properties at the expense of others.
Mechanically, #5 outperforms #3 in strength and hardness. Typical tensile strength for #3 is around 283 MPa, compared to 310-317 MPa for #5. Zinc #5 also exhibits higher yield strength (around 240 MPa vs. 221 MPa for zinc #3) and Brinell hardness (90-91 vs. 82). These enhancements make zinc #5 ideal for high-stress applications, such as automotive components, hardware fittings, and structural parts requiring wear resistance and creep performance. However, zinc #3 provides better ductility and elongation, reducing brittleness and improving performance in applications needing flexibility or impact resistance.
In Zinc Diecastings, Castability favors zinc #3, which boasts superior fluidity for thin-walled, intricate geometries with minimal porosity. zinc #5’s copper addition can slightly increase porosity if not tightly controlled, though it offers marginally better plating and finishing qualities. Dimensional stability remains excellent for both, with zinc #3 holding a slight edge in long-term precision.
Cost is another factor: Zinc#3 is generally more economical due to lower copper levels and broader availability, making it the default choice for general-purpose components like electrical housings, toys, and decorative hardware. Zinc#5’s premium pricing (often 5-10% higher) is justified in demanding scenarios.
Corrosion resistance is comparable, though zinc#3 performs better in copper-sensitive environments. Both alloys excel in surface treatments like chrome plating, painting, and powder coating.
For a Zinc Die Casting Company Alloy #3 remains the versatile, cost-effective standard for most applications, while Zinc Die Casting Alloy #5 provides enhanced strength and durability where performance demands it. Choosing between them hinges on balancing mechanical needs, design complexity, and budget in modern manufacturing.
Permalink: https://www.kineticdiecasting.com/kdc/key-differences-between-3-and-5-zinc-die-casting-alloys/
|
Kinetic Die Casting Company, Inc. 6918 Beck Avenue, North Hollywood, California USA 91605 E-mail sales@kineticdiecasting.com (818) 982-9200 California Die Castings – Die Casting Photos – Technical FAQ – Die Casting Prices – Kinetic Die Casting Company What is Die Casting ? – Why Use Die Casting – Kinetic Abilities – Die Casting Offshore ? – Sand casting prices and die castings – Die Casting Tooling – Kinetic Newsletter |
If you no longer wish to receive these emails, you may unsubscribe here.
Posted in Blogger, Die Casting Parts, Diecasting Process, newsletter
Tagged #Zinc, #ZincDieCasting, #ZincParts
Leave a comment
Aluminum Die Casting Parts vs. Zinc Die Casting Parts: Key Differences
Die casting is a high-pressure manufacturing process used to produce precise metal components with complex geometries. Aluminum and zinc are two of the most common alloys employed, but the resulting parts differ significantly due to their inherent material properties, casting behaviors, and performance characteristics.
Aluminum vs Zinc
Die Casting Part Prices
Weight and Density — Aluminum die cast parts are significantly lighter, with a density of about 2.7 g/cm³ compared to zinc alloy’s 7.1 g/cm. This makes aluminum ideal for applications where reducing weight is critical, such as automotive components, aerospace parts, and electronics housings. Zinc parts, being heavier, provide greater stability and impact resistance, suiting structural or vibration-dampening uses.
Strength and Mechanical Properties — Aluminum alloys offer superior strength-to-weight ratios and better performance at elevated temperatures, with higher tensile strength and the ability to be heat-treated for enhanced durability. Zinc parts excel in ductility, impact toughness, and hardness, often outperforming aluminum in sheer impact resistance despite lower overall strength.
Precision and Design Capabilities — Zinc’s excellent fluidity and lower melting point (~419°C vs. aluminum’s ~660°C) allow for thinner walls (as low as 0.6 mm), tighter tolerances, and finer details. This makes zinc parts better for intricate, small-to-medium-sized components with high cosmetic requirements. Aluminum parts can achieve thin walls but typically require thicker sections and are suited to larger, more robust designs.
Die Castings Surface Finish and Aesthetics — Zinc castings generally provide a smoother, more uniform surface with fewer defects like porosity, making them easier and more cost-effective to plate, polish, or paint for decorative or high-quality finishes (e.g., chrome-plated hardware). Aluminum surfaces are often rougher and more porous, requiring additional post-processing for comparable aesthetics.
Corrosion Resistance and Durability — Both are corrosion-resistant, but zinc offers slightly better natural resistance in harsh environments. Aluminum parts excel in high-temperature applications and have excellent thermal and electrical conductivity, often used for heat sinks or enclosures.
Production and Cost Factors — Zinc’s lower melting point enables hot-chamber die casting, faster cycle times, and much longer die life (often over 1 million shots vs. aluminum’s 100,000–150,000). This reduces tooling costs for high-volume runs. Aluminum uses cold-chamber machines, which are slower and more energy-intensive but support larger parts. Material costs vary, but zinc parts can be more expensive per unit due to higher density.
Aluminum die casting parts shine in lightweight, high-strength, and thermally demanding applications, while zinc die casting parts excels in precision, intricate details, superior finishes, and cost-effective high-volume production of smaller components. The choice depends on the specific requirements for weight, strength, aesthetics, and production economics.
|
Kinetic Die Casting Company, Inc. 6918 Beck Avenue, North Hollywood, California USA 91605 E-mail sales@kineticdiecasting.com (818) 982-9200 California Die Castings – Die Casting Photos – Technical FAQ – Die Casting Prices – Kinetic Die Casting Company What is Die Casting ? – Why Use Die Casting – Kinetic Abilities – Die Casting Offshore ? – Sand casting prices and die castings – Die Casting Tooling – Kinetic Newsletter |
If you no longer wish to receive these emails, you may unsubscribe here.
