A Winner for Mass Production – Die Casting

Die casting is a metal casting process for series or mass production. Cast alloys with a low melting point are typically used for this purpose.

Die casting can produce high-precision components from low-melting alloys, such as aluminum, zinc, stainless steel, or magnesium, with very high surface qualities. From an economic perspective, the process is particularly worthwhile for large-scale series production.

Manufacturing process

Advantages
Die casting has various advantages:

  • The die casting process offers high production efficiency and dimensional tolerance. It produces parts with high durability and dimensional accuracy. Even under harsh conditions, the parts retain their dimensional accuracy. Therefore, die casting is used in the production of complex and internal machine parts that require high levels of precision and accuracy. Die casting adheres to tight tolerances, meaning parts are manufactured with minimal deviations. The excellent dimensional accuracy eliminates the need for machining and improves alloy utilization.
  • Die casting makes it easy to produce thin-walled parts and internal components that require high precision standards. Aluminum die casting enables the production of complex-shaped and lightweight components with an excellent strength-to-weight ratio. This gives the company a significant advantage over other metal castings and investment castings. Aluminum alloy die castings can have a thickness as low as 0.5 mm, while zinc castings can have wall thicknesses as low as 0.3 mm.

    The final products are parts with a fine crystal structure and excellent mechanical properties. Because the liquid metal solidifies under high pressure, the product appears fine, compact, and crystalline. The parts are rigid and exhibit high hardness and strength. They also have improved durability and high conductivity.

  • Die casting is an economical manufacturing process, especially for large-scale production. This is because little to no post-processing is required. This lowers costs and makes the process more economical overall. Die casting machines, molds, and other necessary equipment are very expensive; however, mass production contributes to a better cost distribution throughout the entire production process.
  • The process incurs low post-processing costs because the manufactured parts have a high surface quality. Provided the die is well-shaped and the process is in the right condition, the parts appear fine, smooth, and uniform. Die casting produces shiny parts. Therefore, apart from customer-specific requirements, fewer additional post-processing operations are required.

Sectors

Automotive Industry

Metal parts manufactured using die casting are used in a variety of industries. One of the largest industries using die castings is the automotive industry. Vehicles must be lightweight and efficient. Factors such as fuel consumption, durability, ease of repair, and emissions are all related to weight in some way. Aluminum die casting is the most popular method for producing parts for engines, axles, and other fasteners.

Construction

The second major industry using die castings is construction. Historically, the manufacturing process was primarily used for the production of window and building moldings, as well as some lighting fixtures. Today, it is increasingly used in the construction industry, as its high electrical and thermal conductivity reinforce aluminum as the preferred material for construction.

Electronics

Before our mobile phones mutated into small pocket computers, they consisted primarily of plastic parts. With Apple’s first iPhone and the start of a new decade, a course correction occurred: Since mobile phones now required extreme processing power and calculations that heated the casing, aluminum was used for cooling. In addition to mobile phones, aluminum components can also be found in other electronic devices, such as fluorescent lamps and washing machines.

Energy and Mining

The importance of wind energy as a power source is increasing. Numerous companies currently produce wind turbines and storage systems, as well as transport equipment for these types of systems. Lightweight, electrically conductive die-cast parts play an important role here as well.

However, the need for lightweight equipment continues even in older mining operations, such as drills or customized drilling and mining equipment.

Aerospace

In no other industrial sector is the need for lightweight, corrosion-resistant parts greater than in aerospace engineering. Parts made from die-cast aluminum were used in the first manned mission to the moon. Today, for example, propellers and other important components of aircraft and rockets are manufactured using aluminum castings.

Furniture and Decoration

Not only in home construction, but also in interior design, there are numerous applications for die-cast aluminum parts: From tables and bookshelves to pendant lamps and table stands, aluminum profiles and die-cast parts can be found in almost every room.

Service

We at OESTERLE® GmbH are specialists in molded parts made of all metals and plastics. Because your part should be as unique as your ideas, you shouldn’t settle for standard products. We have the ideal technology for every part. Contact us – we’ll take the time to listen to your needs and will be happy to advise you in detail, including on other manufacturing processes such as investment casting, sintering, machining, MIM technology, and other processes.

Still not convinced? Then take a look at our case studies. OESTERLE® GmbH – We cultivate partnerships on equal terms and always strive for the highest quality.

E-mail

Request email

Phone

Call