As winner of numerous international awards, Bruschi Spa is known for its innovative approach in design and technology. We are glad to share our insights and experiences with the industry members.

Optimizing the filling process in high pressure die casting

by Stefano Polli November 16, 2016

In high pressure die casting, the filling process is crucial for the product esthetical quality and mechanical characteristics, for reducing scraps and optimizing set up parameters, and also for the maintenance and life cycle of the die.

HPDC filling process

The filling order of the different parts of the die and the air vents positions influence the homogeneity of the cast components and can avoid air entrapment. The filling process is determined by the geometry of the die and the design of the gating system. The geometric complexity of the dies can lead to a fluid flow without any surface fragmentation.


An improved high pressure die casting design means both product quality and process optimization

The control of the die filling becomes more effective with a casting simulation software which can model the molten metal flow and its solidification. It is a useful tool for having a virtual analysis of the molten metal flow in the mould and it can provide very useful information in order to optimize the filling process.

The data collected during the simulation phase are the key features of every high pressure die casting process (filling velocity, runner and gate effectiveness), and can help preventing common defects, such as air entrapment and premature solidification.

In addition, the pre-production design phase is shortened as the software can calculate the efficiency of a mould avoiding the high costs of test castings and experiments.

To examine and optimize a high pressure die casting filling process, a simulation software is the perfect tool as it supports the mould design phase and prevents any issues and defects. After the simulation of the filling phase it is possible to identify problems and modify the geometry of the casting and the gating system accordingly.

The main causes of problems in the filling process of high pressure die casting arepoor geometry of the 

  • poor geometry of the casting which can cause an improper filling configuration
  • gating system which can lead to an irregular solidification process

In high pressure die casting you often consider complex parts, therefore it is impossible to predict the mould filling phase without a virtual simulation of the process to guarantee high quality standards in the design. A simulation program helps the caster saving time and reducing costs of the mould design (the number of test castings is reduced) and this can lead to a better quality of the product, a shortened time to market, and of course a cost reduction for customers as well.

Optimizing the filling process in high pressure die casting means to identify the perfect gate size and location, the runner system design which ensures a balanced and complete filling of the mould and avoids air entrapment.

Bruschi engineers are able to monitor and optimize each manufacturing process phase, including the filling one, to ensure the quality and conformity of the final product.
Our technical staff is available to support your designer’s inventiveness and to develop innovative and creative solutions together.

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