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How to save during Die Casting Process

by Martina Fagnani March 3, 2017

Zinc die casting process can have important advantages compared to other manufacturing process: for example can lead to major cost savings during production cycle, allows to create complex product shapes and is possible to eliminate unnecessary assembly operations combining multiple components into a single one.


Die casting process


Die casting process: reducing costs

Why use zinc?

Zinc metal is the perfect choice for many reason, for its decorative and functional applications.

Zinc is a dense metal, really durable, strong and allows many die casting finishes compared to other materials. Furthermore is possible to die cast zinc at moderate temperature, for example compared to aluminum: this means saving in terms of energy and processing over other alloys.

These zinc characteristics are crucial for functional and aesthetic reasons: from surface improvement to design.

Zinc alloys can be the right materials to develop products or components because they can be finished in a variety of techniques however, in particular for functional parts, the majority are used without any surface coating. Due to zinc characteristics, this material is acceptable for uses in uncoated state: this allows an important cost saving.

But it is not just zinc making the difference. During zinc die casting process is fundamental a collaboration between client and supplier in order to improve the component or product. This can be done for example with a co-design activity. Zinc allows several morphological innovations, saving and mass production: the supplier expertise will do the rest.


Reducing costs in zinc die casting

There are several ways where is possible to save during zinc die casting process. For example, the most important are:

  • Simulation phase
  • Co-design service
  • Work on surface treatments

Simulation phase

Cost reduction in simulation phase can be applied widening simulation phase. Simulation, developed at the very beginning of product design, is a key point of die casting process.

Simulation software, such as MAGMASOFT, have been allowed by a higher computing power and innovative algorithms. These tools help designers to avoid any defect and problem during the process and allow processes simulation of material inside mould cavity.

With these particular software is possible to modify the product and its performances already during the beginning of product design phase. This software allow the specialist to analyze real time data to identify critical points and, since the beginning, specialists can simulate defects and modify the die casting process in order to avoid issues. Everything is done in order to avoid material and time waste.


Co-design service

In order to reach a significant cost reduction zinc die casters can offer to their customers a co-design service. This service is done to improve product design or functionality, or reduce costs thanks to the collaboration between client and supplier.

Is fundamental for the supplier to take into account the entire production process. In this way is possible to improve products or components performances. Moreover every zinc die casting manufacturer should have a dedicate engineering department, focused on analysis and simulation. Die casting manufacturers should have the chance to do prototyping right inside the structure, using pilot tools.

This is an approach applied to guarantee the client a full support in order to improve components during product design phase.


Surface treatments

Surface treatments cycle need to be optimized in order to produce a finished product aligned with clients expectations. Often is the client who gives precise indications about the correct cycle, otherwise is the designer who, in strict collaboration with its client, suggests the most suitable process.

The process is normally divided into three steps: the first one is dedicated to polish parts and eliminate marks such as part lines, created during die casting process, the second one prepares the component for the real surface treatment choosing the most suitable solution for the product, the third one regard strictly surface treatments application.

Surface treatments done in the same plant as die casting allows the client to have finished or semi-finished products using only one supplier to cut costs and simplify the process.

All this process has to be done in order to avoid secondary and unnecessary operation which will raise costs.

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