When designing for die casting, consider: uniform wall thickness to prevent cooling issues, appropriate draft angles (typically 1-3°) for part ejection, corner and edge radii to improve flow and reduce stress concentration, the location of parting lines, minimizing undercuts, and incorporating features that reduce secondary operations. Our engineering team can review your designs to ensure optimal manufacturability.

Alloy selection depends on multiple factors including: mechanical property requirements (strength, elongation, hardness), service conditions (temperature, environment), post-casting processes (machining, heat treatment, surface treatments), cost considerations, and dimensional stability needs. We conduct thorough analysis of your application requirements and may recommend material testing to ensure the optimal alloy choice.

To reduce porosity, design modifications include: optimizing wall thickness transitions to prevent air entrapment, incorporating overflow wells and vents at the end of metal flow paths, adding vacuum assist features to remove air during filling, strategic positioning of gates and runners to ensure laminar flow, and avoiding thick sections where shrinkage porosity can occur. We also implement process-based solutions like optimized fill speeds and intensification pressure profiles.

Advanced simulation software allows us to predict and optimize metal flow, solidification patterns, thermal behavior, and potential defects before manufacturing begins. This virtual prototyping reduces development cycles, minimizes die design iterations, optimizes gate and runner designs, predicts and eliminates air entrapment issues, and ensures proper thermal management of the die. Our simulation capabilities typically reduce development time by 30-40%.

Converting machined parts to die castings requires: redesigning for die casting manufacturability (adding draft, radii, etc.), evaluating material property equivalence between wrought and cast alloys, determining critical dimensions and tolerances achievable with die casting, identifying areas requiring machining allowances, and conducting cost-benefit analysis including tooling investment vs. piece price reduction. We provide comprehensive conversion analysis to maximize the benefits of die casting while maintaining functional requirements.

Our innovative technologies include: conformal cooling channels created through additive manufacturing for improved thermal management, multi-material die components combining high-conductivity alloys with high-strength steels, vacuum-assisted systems for superior internal quality, real-time process monitoring with adaptive control systems, advanced surface treatments for extended die life, and simulation-driven optimization to achieve previously impossible geometries. We continuously integrate new technologies to push the boundaries of what's possible in die casting.