Why Should a Engineering/Design
Student
Be Interested in the Die Casting Process?Die casting is a proven manufacturing process by which strong, highly durable, and
incredibly intricate products are being produced in volume, from tiny electronic parts to
truck transmission cases. Through advanced production technologies, die casting can
execute a product designer's conception in sculptured metal at the lowest unit cost.
Shortest Time From Raw Material to Finished Part: Any student of mechanical,
manufacturing or materials engineering who is planning a future career that deals with the
design and production of functional or decorative products will want to be familiar with
the potential processes that can produce his or her designs. Die casting, also referred to
as high-pressure casting, has the unique ability to transform its raw material into
accurately dimensioned and smoothly finished form in the shortest possible cycle time.
Greater Design Freedom: A designer can plan for the execution of a product form
as a net-shape die casting with far greater freedom and flexibility than with any other
metalforming process. Choosing die cast manufacturing allows the designer to eliminate
costly multiple-part assemblies and the extensive machining of holes, surfaces and complex
features to final tolerances.
Superiorities Over Plastics: With similarities to the plastic injection molding
process, die casting can make parts to the final shape specified by the designer, often
with no additional machining or other operations required. Unlike plastics, however, die
castings can generally be produced to tighter and dimensionally stable specifications, in
a range of non-ferrous alloys--providing the look, feel and durability of metal.
Conversions from Iron, Steel, Bronze: With recent advances in high-pressure
casting and alloy compositions, components designed for highest
strength in iron, steel or bronze are now being cast as near-net-shape high-density
ferrous metal parts at significant weight and cost savings.
In Tune With Designing for Recyclability: As more and more companies, and
countries of the world, are requiring new products to be designed for their eventual
recycling, die cast parts are uniquely suited to these new "green design"
specifications. Over 95% of all aluminum die castings, for example, are today produced
from post-consumer recycled metal alloy.