Cast in Motion | NADCA's 2027 Student Die Casting Design Challenge

CAST IN MOTION

NADCA's 2027 Student Die Casting Design Challenge

Design it. Engineer it for die casting. See it fly.

 

The North American Die Casting Association (NADCA) invites high school and college students across North America to take on a new kind of engineering challenge: engineer a die-cast aluminum chassis for a working drone platform — then see it tooled, cast, and flown.

This isn't just a design contest. Each division's winning entry will be handed off to a NADCA manufacturing partner, who will build real production tooling and cast the part. Qualifying teams will then receive a standard drone kit and a production casting to finish, assemble, and fly at NADCA's October 2027 Congress in Indianapolis, Indiana — a real, die-cast product born from student engineering.

Cast in Motion is NADCA's newest program to connect the next generation of engineers and designers with the die casting industry, following in the spirit of programs like Cast in Steel that have introduced thousands of students to the art and science of metal casting.

Who Can Enter

High School DivisionOpen to teams or individuals currently enrolled in a U.S. or Canadian high school, with a faculty/teacher advisor.
College/University DivisionOpen to teams or individuals currently enrolled in an undergraduate or graduate program, with a faculty advisor.

Teams may include 2 to 6 members. Each entry must have a designated advisor of record who can confirm eligibility and support the team throughout the challenge.

The Challenge

NADCA will supply each registered team with a standard drone kit — electronics, camera, motors, folding arms, battery, and controls — along with a released CAD interface envelope defining the space available for the drone's central body/chassis.

Entrants are asked to:

  • Design a central drone body/chassis that fits the standard interface envelope and is both interesting — creative, distinctive, and memorable — and functional as a high-pressure die casting.
  • Target a nominal wall thickness of 2.5 mm, within a design window of 2.0–3.0 mm outside of approved ribs, bosses, or reinforced features.
  • Submit a complete die casting data package for the component.

The data package should include, at minimum:

  • Part drawings or CAD files for the component
  • Recommended die casting alloy grade (aluminum) and rationale
  • Wall thickness, draft angle, and general design-for-manufacturability notes
  • Recommendations on gating, parting line, or tooling considerations
  • Predicted casting mass and supporting mass/center-of-gravity calculations
NADCA will provide educational resources and mentor support throughout the design period to help teams new to die casting complete a strong submission — no prior casting experience is required to enter.

Key Dates

October 2026
Registration opens
November 2026
Registration closes
January 2027
Design interface package and rules released; design period begins
January – April 2027
Design support: mentor Q&A and technical resources available
May 2027
Final submission deadline (CAD, drawings, and die casting data package)
May 2027
Judging and winners announced — one per division
Summer 2027
Winning designs tooled and cast by a NADCA manufacturing partner
September 2027
Production castings and drone kits shipped to qualifying teams
September – October 2027
Student finishing, assembly, and flight verification
October 2027
Winning die-cast drones unveiled and flown live at NADCA's Congress in Indianapolis, IN

Judging Criteria

Category Points What Judges Evaluate
Die Casting Manufacturability 25 Wall strategy, draft, radii, ribs/bosses, parting/ejection concept, realistic HPDC geometry
Weight & Material Efficiency 15 Predicted casting mass and efficient use of material
Structural Design 15 Stiffness, load paths, mounting integrity, protection of electronics
Innovation 10 Creative engineering solution without sacrificing manufacturability
Aesthetics 10 Form, integration, and visual identity
Assembly & Serviceability 10 Simple assembly, access, fastening, and component replacement
Engineering Analysis / Simulation 10 Mass properties, CG, DFM evidence, optional fill/solidification or structural analysis
Presentation 5 Clear drawings, rationale, and technical communication
Total 100

Entries will be evaluated in two rounds. All qualifying entries are scored against the rubric above; a shortlist of finalists per division will be invited to present their design before final scores are set. All judging will be completed by May 2027.

What Winners Receive

  • Their winning component tooled and cast into a finished drone by a NADCA manufacturing partner.
  • A live flight demonstration of their design at NADCA's October 2027 Congress in Indianapolis, Indiana.
  • Recognition and prize/scholarship support (details to be announced).
  • Direct engagement with die casting industry professionals and potential career pathways into manufacturing.
  • All qualifying teams — not just the division winner — will receive a production drone kit and casting to finish, assemble, and fly at Congress.

Suggested recognition categories

Overall Design Winner, Best Die Casting Design, Lowest-Mass Casting, Best Appearance, Best Engineering Analysis, Best Flight Demonstration, and People's Choice.

How to Enter

Registration opens October 2026 at diecasting.org/castinmotion . Registration closes January 2027; the design interface package and rules are released in January 2027, and final submissions — CAD, drawings, and die casting data package — are due in May 2027.

Questions? Contact Paul Brancaleon, NADCA Executive Director of Research, Education and Technology, at castinmotion@diecasting.org or visit diecasting.org  for updates.

About NADCA

The North American Die Casting Association is the premier trade organization serving the die casting industry, supporting members across the United States, Canada, and Mexico through research, education, and industry advocacy.