A well-designed approach can significantly improve your manufacturing experience. If you’re new to the aluminum die casting supplier business or want to brush up on your die casting design skills, this aluminum die casting design guide is for you. This design guidance would be beneficial to mechanical engineers and product designers. We discussed critical design considerations and constraints that can greatly simplify the aluminum die casting process, hence lowering the costs of the casting factory.


Design Requirement:

When creating an aluminum die-cast part, the application, aesthetic, performance, precision, and, most significantly, the cost must all be considered. To begin, as a casting supplier you must choose what you want to accomplish in each of your components and balance your objectives to stay within your budget. We’ve highlighted the critical points to consider while developing a part in this section.

Using Function:

When creating a product, it is necessary to consider its intended use. Aluminum die-cast components can be used for structural as well as cosmetic purposes. As a result, it has become a popular substitute for others.

Due to the fact that modern computers are significantly more powerful than previous generations, the accuracy achievable through die casting has increased by a factor of ten. Along with their high structural integrity, die-cast components also have an excellent visual appearance.

You should specify precisely how your components will be used by the die caster. He can assist you in selecting the appropriate material and establishing appropriate tolerances for design parameters based on your requirements. Additionally, you should consider corrosion resistance, strength-to-weight ratio, and conductivity.

However, customers frequently end up paying for a level of quality and strength that considerably surpasses their requirements. Thus, having a firm grasp on the intended use of your components will provide you with a better understanding of the die casting manufacturer process.

Appearance Requirement:

The appearance of an interior aluminum die casting component is largely irrelevant. However, it is critical when the component is an external casting, such as a housing or casing.

End users will always have a preference for visually appealing products. Thus, regardless of a component’s effectiveness, buyers will place a premium on its appearance. As a result, external die-cast components should be attractive.

As a result, you should design your components with aesthetics in mind. Prepare in advance for the type of surface finishing you desire. A high-quality finish can give another layer of protection against adverse weather conditions. 

die casting

Assembly Method

Assembly of aluminum dies casting components can be reasonably straightforward or quite complex, depending on the intricacy of the components. Die casting factory machinery used in the past had some limitations on the types of items that could be cast. Thus, casting intricately detailed pieces was previously difficult.

However, complex items can be separated into suitable segments and then assembled using a suitable assembly method after casting. Several typical die-casting assembly procedures include the following:

  • Fastening
  • Threading
  • Welding
  • Injected Metal Assembly
  • Cored Holes, etc.

Before you begin designing, you must decide on a certain assembly approach for your die-cast components. Because the assembling process has a significant impact on the design. Select an assembly method that is best for your needs.

Cost Budget:

You should conduct a thorough cost study of your project. Because financial constraints have a direct impact on your die casting manufacturer firm. Your design must be completed in accordance with your budget.

A skilled designer can significantly cut die casting costs without sacrificing the quality of your components. To avoid overdesigning your components and incurring extra expenditures, you should adhere to specific design standards.

For instance, by including pockets, you can create lighter components without sacrificing performance. It enables you to save money on materials. Then, by minimizing or eliminating undercuts and sharp corners, the cost and difficulty of tooling and casting can be significantly reduced.

Product Structure Design:

Designing an aluminum die-cast item properly has numerous obstacles. Even the tiniest details in a design can significantly affect the casting factory process. As a result, each detail should be carefully considered in accordance with the specified criteria.

We have concentrated on the primary characteristics of aluminum die casting design. You’ll discover recommended precisions for a variety of critical aspects and learn about the design concerns you should keep in mind while developing your product.

Material Selection:

The design of the product might change greatly based on the material used. Certain restrictions will be imposed on each type of alloy. To ensure the integrity and strength of your aluminum die-cast components, rigorous design and execution are required.

Aluminum’s qualities, such as weight, fluidity, strength, conductivity, and melting temperature, can vary according to the alloying elements used. However, not all of them are acceptable for use in die casting.

Several popular aluminum alloys for die casting include the following:

  •     A380
  •     A383 (ADC12)
  •     A413

Additionally, numerous other aluminum alloys are available. You must select the appropriate aluminum alloy based on your specifications and budget constraints.