Modern die cast manufacturers use a number of sophisticated methods in die casting dies. This method includes an automated system to provide and assure quality control in die cast products. It can be used in different functions like to lubricate dies, pour molten metal into the chamber machine, quenching and trimming castings. Die cast tooling called insert die, die casting dies, or die casting molds, comes in various forms and styles, sizes, and prices. Die cast tooling comes in single cavities or one part each cycle or multiple cavities or more than one part each cycle. Most often die casters only use cold chamber machine tooling dies or molds for aluminum die cast parts. Aluminum die casting dies can be stronger than steel. High pressure die casting process is use to make aluminum die casting dies and many other kinds of die cast aluminum parts. Die cast tooling costs from a few hundred dollars for trim dies, a few thousand dollars for cavity inserts, and several thousand dollars for a large part complete die casting dietool package.
Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is important that companies collaborate with the die caster at an early stage of the product design and development. Proper consultation with the die caster during the process will help resolve issues affecting tooling and production and likewise affecting overall costs.
For instance, there are parts having external undercuts or projections on sidewalls often require dies with slides. Slides increase the cost of the tooling, but may reduce in metal use, uniform casting wall thickness or other advantages. Another thing to consider in designing die casting die is choosing the right type of alloys and their properties. The cost of materials that are needed with accurate comparisons on their strength like for instance, the relatively greater strength of metals generally allows thinner walls and sections and requires lesser cubic inches of material. All these may offset the cost of tooling, depending upon the production quantities and all other economic issues.
There are many sources available for information on the designs of die casting dies. These include textbooks, technical papers, trade journals, even professional associations. There are factors to consider when choosing die casting designs and manufacturers must know this before choosing the dies for their products.