How Metals, Plastics, and Machine Choice Impact the Die Casting Process

ELK GROVE VILLAGE, IL, January 4,2024

From an idea to a tangible product, product creation is both an art and a science. This process requires creativity, as well as knowledge of materials and manufacturing techniques. It's especially true for die casting, where design choices and machinery have a big impact on the final product.

This article provides a comprehensive guide to informed material choices in die casting and offers advice on how to make the process more streamlined, ultimately leading to improved manufacturing outcomes.

5 Key Considerations in Material Selection for Die Casting

1. Function-First Approach

This functional aspect often dictates the shape, strength, and even the material of the product. For instance, a product designed to handle heavy loads will have different material requirements than one that is purely decorative.

2. Metal vs. Plastic Dilemma

Material selection for die-casting often boils down to metal versus plastic. Metals are typically stronger and heavier, often perceived as more premium, but they can also be more expensive. Plastics, on the other hand, offer versatility in colors and forms but vary greatly in strength and durability. It's interesting to note that metals are generally 2 to 3 times stronger per cross-section than plastics and high-performance plastics can be more expensive per cubic inch. 

3. Design Complexity

Consider a door handle. At first glance, it seems simple, but its design is a complex interplay of aesthetics and functionality. The choice of material here isn't just about the designer’s vision but also the engineer's challenge in realizing that vision.

4. Material Characteristics

Metals and plastics both come in a wide array of types, each with its unique properties. Metals like brass, bronze, aluminum, and magnesium differ in color, strength, and cost. Similarly, plastics can range significantly in durability and be easily colored through additives.

5. Impact of Finishing Processes

Finishing processes heavily influence a product's overall appearance and cost. For instance, plastics can often be colored naturally, while metals require various treatments to achieve the desired look and performance. Ultimately, the choice of a shiny polished appearance or a natural finish can dramatically alter the aesthetic appeal. It is important to understand that the plastic or metal material might represent only a small fraction of the final product's cost.

Making Material Selection Simpler: Cold Chamber Die Casting

When it comes to manufacturing, the choice of how to make the first, the millionth, and the last product is pivotal. Cold chamber die casting is versatile enough to handle nearly any material, offering a solution that aligns with both aesthetic and functional requirements.

Cold chamber die casting is unique from its counterpart, the hot chamber process, in several key aspects. 

• Cold chamber die casting produces a near-net shape product by enabling high-precision and detailed components with minimal waste, opposed to other processes that require secondary operations such as bolt holes or gasket grooves.
• It is designed to handle metals that would otherwise damage hot chamber machines due to their high melting points or corrosion nature of the material. 
• It enables manufacturers to experiment with various metals, each offering unique properties like strength, weight, and corrosion resistance. This flexibility is crucial for industries where material properties directly impact product performance, such as automotive, aerospace, and electronics.
• This process offers high precision and control over the final product's properties. By adjusting parameters like injection pressure, speed, and die temperature, manufacturers can fine-tune the density, surface finish, and structural integrity of near-net shape cast parts. 
• Cold chamber die casting enables high-volume production without quality compromise. The process is highly efficient, capable of producing complex shapes with close tolerances and minimal waste. 

Bridging Material and Machine for Innovation in Die Casting

Shibaura Machine Company, America understands that the right material choice is just the beginning in the journey from concept to final product. The final product reflects not only the idea you had, but also the material and manufacturing decisions made.

Regardless of the material, our state-of-the-art cold chamber die casting machines ensure precision, efficiency, and quality. 

Contact our Die Casting team to learn more.

Achieving manufacturing excellence has never been easier. 

Contact the Die Casting team to learn more:

• Phone: (888) 593-1616
• Email: dc-sales@shibaura-machine.com