Die Casting Experience
Basic Aluminum has had significant experience with a wide variety of applications with specific product requirements. These include:
Powertrain Components: These castings are used in engine and transmission applications on a number of different platforms. These die castings have tight tolerance requirements for critical characteristics. They are required to be pressure tight and have specific porosity requirement after machining. Basic has been responsible for the machining and has supplied unmachined die castings to customers which machine certain dimensions to size. Due to the exacting requirements for this type of application, Basic Aluminum has installed extensive metal control, process control and quality control processes throughout the facility to minimize variation and potential problems.
Assembled Components and Finished Castings: In addition to providing a casting, Basic has extensive experience providing completed assemblies to meet customer requirements. Depending on the operation, Basic will either carry out the process at Basic (machining, shotblasting, assembly) or outsource and manage the process (painting, vibratory deburring, etc) to a local supplier.
Heat Sinks: These products present their own unique requirements as the integrity of the casting and fins are critical to the long term function of the assembled component. Basic utilizes specific design standards on die cast dies to prevent long term problems and minimize casting variation on heat sink product lines.
High Finish Die Castings: Basic has supplied several products which are used by end customers, such as vaccuum cleaner parts which have exacting visual appearance requirements. Basic maintains visual standards appropriate to the product to ensure consistent casting quality. The process is designed appropriately to give a fill and finish which meeds customer needs.
Die Casting Die Casting Die Casting Painted
New Die Casting Products
When a manufacturer is building a new product, they may find that a die casting part is a good fit for all or part of the application. The die casting process is capable making products with intricate shapes, thin walls and can meet pressure tight requirements. In higher volumes, die castings are very cost competitive due to their short cycle times relative to other processes.
In designing a part intended for die casting, many different aspects of the part must be evaluated including wall thickness, draft, machining locator placement, etc. Working with our experienced die cast engineers early in the process can reduce cost and potential quality problems.
Our design involvement encompasses the total environment of a customer’s product. Consideration is given to the casting process, machining and finishing processes, assembly issues, interfaces with mating components and how the product is perceived by the final end user. Time spent early in the design phase translates into valuable benefits for our customers and ourselves.
Once a product is designed, tooling must be built. This may include:
Multiple dies if annual volumes are high enough to warrant it
Gages and part testers
After the die cast tooling has been manufactured, it must be sampled and tested to verify that it produces parts which meet product requirements.
Basic has significant die casting experience and can assist manufacturers in this process to ensure that part deadlines are met in an economical fashion while meeting part quality and functional requirements.
Die Casting Solid Model
Die Casting Transfer Tooling and Products
Occasionally the need arises to transfer existing die cast tooling from one die casting supplier to another. The reasons behind this are varied and may include bankruptcy, quality problems, capacity and others. When transferring tools, many steps have to occur. These include:
Ensure that there is enough die castings made from the current supplier to cover production needs.
Move die cast tooling and support equipment such as trim dies to the new supplier
Check and possibly modify the die cast die to make sure that it fits the new company’s die cast machines. This adaption is usually pretty simple, but every die cast machine manufacturer has some differences in clamping, ejection, shot position, etc.
Make sample castings at the new company and qualify them by the customer (often through a PPAP process)
These steps must take place in a relatively short time frame to prevent production interruptions.
Basic Aluminum has significant experience with transfer tooling projects and can help customers who find themselves in need of open die casting capacity. For specifics, please contact us.
If you are considering a tool transfer, E-mail us for our document:
Considerations when Transferring Tooling