Die Casting
Die casting is used to produce high-quality metal parts and components, It involves injecting molten metal into a mold cavity under high pressure, which then solidifies to form the final product, Die casting is a versatile process that can be used to produce complex and intricate parts with a high degree of accuracy and consistency.
Die casting is used in a wide range of industries, including aerospace, automotive, electronics, and medical devices. It’s a popular manufacturing process because it allows for the creation of complex parts with high precision and accuracy. Additionally, die casting is a cost-effective process because it produces very little waste and can be used with a wide range of metals, including aluminum, zinc, and copper.
Die Casting Service Description
Name Description Material Aluminum, Zinc, Copper, Iron… Piece weight 1 g – 20 kg Piece thickness ≥ 0.5mm Surface Roughness Ra1.6~Ra6.3 Accuracy ISO8062 CT4~CT11, ISO2768 F/M Cavity Single or multiple Mold Life Time 50K – 150K times Size According to customers’ drawings or samples Drawing Format STEP, STP, PRT, IGS, XT, STL, X_T, DWG, DXF, pdf Process Casting +Machining(option)+surface Treatment Surface treatment Sanblasting, Polishing, Plating, Powder Coating, Anodisation etc Testing Machine Profile projector, Rockwell hardness tester, Vickers hardness tester,
Roughness tester, air gage, concentricity tester, universal microscope,
CMM, digital caliper and etc.Certificate ISO9001: 2015 MOQ: Comply with customer’s demand Applications Machinery Accessories, Construction Parts, Agriculture Parts, Auto parts… Payment Method: T/T, Paypal, Western Union Shipping Method: Express(DHL, Fedex, UPS, EMS), air-freight, ocean-freight
Casting Linear Dimension Tolerances（ISO8062）
| Nominal Dimension | Linear Dimension Tolerances（ISO8062） | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| > | ≤ | CT4 | CT5 | CT6 | CT7 | CT8 | |||||
| – | 10 | 0.26 | ±0.13 | 0.36 | ±0.18 | 0.52 | ±0.26 | 0.74 | ±0.37 | 1 | ±0.5 |
| 10 | 16 | 0.28 | ±0.14 | 0.38 | ±0.19 | 0.54 | ±0.27 | 0.78 | ±0.39 | 1.1 | ±0.55 |
| 16 | 25 | 0.3 | ±0.15 | 0.42 | ±0.21 | 0.58 | ±0.29 | 0.82 | ±0.44 | 1.2 | ±0.6 |
| 25 | 40 | 0.32 | ±0.16 | 0.46 | ±0.23 | 0.64 | ±0.32 | 0.9 | ±0.45 | 1.3 | ±0.65 |
| 40 | 63 | 0.36 | ±0.18 | 0.5 | ±0.25 | 0.7 | ±0.35 | 1 | ±0.50 | 1.4 | ±0.70 |
| 63 | 100 | 0.4 | ±0.20 | 0.56 | ±0.28 | 0.78 | ±0.39 | 1.1 | ±0.55 | 1.6 | ±0.80 |
| 100 | 160 | 0.44 | ±0.22 | 0.62 | ±0.31 | 0.88 | ±0.44 | 1.2 | ±0.60 | 1.8 | ±0.90 |
| 160 | 250 | 0.5 | ±0.25 | 0.7 | ±0.35 | 1 | ±0.50 | 1.4 | ±0.70 | 2 | ±1.0 |
| 250 | 400 | 0.56 | ±0.28 | 0.78 | ±0.39 | 1.1 | ±0.55 | 1.6 | ±0.80 | 2.2 | ±1.1 |
| 400 | 630 | 0.64 | ±0.32 | 0.9 | ±0.45 | 1.2 | ±0.60 | 1.8 | ±0.90 | 2.6 | ±1.3 |
ISO 2768 Tolerance Standard
| Table 1 Length Tolerance（except breakage） | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| Tolerance Class | Size(mm) | ||||||||
| Symbol | Description | 0.5~3 | 3~6 | 30-120 | 120-400 | 400-1200 | 1000-2000 | 2000-4000 | |
| f | Fine | +/-0.05 | +/-0.05 | +/-0.1 | +/-0.15 | +/-0.2 | +/-0.3 | +/-0.5 | — |
| m | Middle | +/-0.1 | +/-0.1 | +/-0.2 | +/-0.3 | +/-0.5 | +/-0.8 | +/-1.2 | +/-2 |
| c | Coarse | +/-0.2 | +/-0.3 | +/-0.5 | +/-0.8 | +/-1.2 | +/-2 | +/-3 | +/-4 |
| v | Vert Coarse | — | +/-0.5 | +/-1 | +/-1.5 | +/-2.5 | +/-4 | +/-5 | +/-8 |
| Size less than 0.5mm, the deviation will be displayed near the relevant normal size | |||||||||
| Table 2 Breakage Tolerance (Outer Radius and Slope height) | |||||||||
| Tolerance Class | Size(mm) | ||||||||
| Symbol | Description | 0.5-3 | >5 | ||||||
| f | Fine | +/-0.2 | +/-0.5 | +/-1 | |||||
| m | Middle | +/-0.2 | +/-0.5 | +/-1 | |||||
| c | Coarse | +/-0.4 | +/-1 | +/-2 | |||||
| v | Vert Coarse | +/-0.4 | +/-1 | +/-2 | |||||
| Size less than 0.5mm, the deviation will be displayed near the relevant normal size | |||||||||
| Table 3 Angle Tolerance | |||||||||
| Tolerance Class | The shorter side length of associated Angle（mm) | ||||||||
| Symbol | Description | 10 | 10-50 | 50-120 | 120-400 | 400 and up | |||
| f | Fine | +/-1° | +/-0°30′ | +/-0°20′ | +/-0°10′ | +/-0°5′ | |||
| m | Middle | +/-1° | +/-0°30′ | +/-0°20′ | +/-0°10′ | +/-0°5′ | |||
| c | Coarse | +/-1°90′ | +/-1° | +/-0°30′ | +/-0°15′ | +/-0°10′ | |||
| v | Vert Coarse | +/-3° | +/-2° | +/-1° | +/-0°90′ | +/-0°20′ | |||
Die Casting Process
Die Casting Pros and Cons
1，High efficiency
Die casting is a highly efficient method of manufacturing parts and components, which makes it an ideal choice for high volume production runs.
2，High accuracy
Die casting produces parts with a high degree of accuracy, which is essential in industries that require precision parts.
3，Wide range of materials
Die casting can be used with a wide range of materials, including aluminum, zinc, magnesium, and copper.
4，Low labor costs
Die casting requires minimal labor, which can help to reduce manufacturing costs.
5，Smooth surface finish
Die casting produces parts with a high-quality surface finish that requires minimal post-processing.
1，High initial investment
Die casting requires a high initial investment in tooling and equipment, which can be a barrier for small businesses.
2，Limited size
Die casting is suitable for small to medium-sized parts and components, which can limit its application in certain industries.
3，Porosity
Die casting can result in parts with porosity or air pockets, which can affect the quality of the part.
4，Limited flexibility
Die casting is not a flexible manufacturing process, and changing the design of the part or component can be costly.
5，Environmental concerns
Die casting can produce hazardous waste, which can be harmful to the environment.
Die-casting products have good quality, stable size, high production efficiency, huge die-casting mold use times, suitable for large quantities of production, good economic benefits.
Casting is easy to produce small porosity and shrinkage, the mechanical properties of the product is not as good as CNC products, small batch investment cost is high.
Mostly we suggest the 3D printing for prototype, CNC processing for small qty, dia casting for large qty demand.
Please send us your requirements, our professional engineers team, will give you the most suitable advice.
Materials for Die Casting
Aluminum Alloy for Casting
| Aluminum: |
|---|
| Aluminum is by far the most commonly used material in die casting. It is lightweight, strong, and highly resistant to corrosion. These properties make it ideal for use in products that require high strength and durability, such as automotive components, aerospace parts, and electronic enclosures. |
| Alloys: |
| ADMT, ADC12, A356, A386, A384, A413, AK5M2, YL113 etc |
| Finish Options: |
| A.Polishing, B.Grinding, C.Brushing, D.Sandblasting, E.Painting, F.Powder Painting, G.Anodizing , H.Hard anodized, I.Teflon Coating, J.Laser Marking, K.Silk Screen, L.Transfer Printing. |
Copper Alloy for Casting
| Copper |
|---|
| Copper is less commonly used in die casting due to its high melting point, but it is sometimes used for specific applications such as electrical connectors and plumbing fittings. Magnesium is another lightweight and strong material that is sometimes used in die casting, particularly in the automotive industry. |
| Alloys: |
| C83800, C84500, C83600, C90700, C90500, C95700, C86800, etc |
| Finish Options: |
| A.Polishing, B.Grinding, C.Brushing, D.Laser Marking, E.Silk Screen, F.Transfer Printing. |
Zinc Alloy for Casting
| Zinc |
|---|
| Zinc is another popular material used in die casting. It is highly malleable, making it easy to cast into complex shapes. Zinc is also very strong and has good electrical conductivity, making it ideal for use in electronic components, as well as in products such as door handles and locks. |
| Alloys: |
| 2#,3#, 4#, 5#, 8#, ZA-8, ZA-12 |
| Finish Options: |
| A. Polishing, B.Grinding, C.Sandblasting, D. Nickle Plating, E.Painting |
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