What is Die Casting?
Die casting is the process of injecting liquid metal under high pressure into a high precision mold. It is used to mass produce complex 3 dimensional structures with a detailed surface texture within a single manufacturing step without post treatment. Since the surface of the die is quickly cooled by the mold, the slowly cooling core creates a negative pressure within the cast metal, which makes it more rigid and increases its structural integrity.
How does Die Casting work?
- The mold is opened
- The mold is cleaned and in some cases surface treated or filled with oxygen
- The liquid metal alloy is poured into the injection piston
- The piston is closed and the metal is forced into the mold
- The metal fills the mold and starts to cool
- The mold opens and the casted solid die is removed
Advantages:
- Complex structures within a single manufacturing step
- Very precise
- Very rigid and durable
- Detailed surface
- High volume
- High yield rate
Disadvantages:
- High tooling/mold costs
- Welding and other post treatment can be problematic
- Depending on process, reduced thermal conductivity
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Comparison | Die casting | Extrusion | Stacked fin | Folded fin | Skived fin |
Cost | medium to low | low | high | medium | low |
Tooling Lead-Time | long | short | long | long | medium |
Weight | medium | heavy | light | light | medium |
Performance | high | limited | best | medium | limited |