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The Pros and Cons of High-Pressure Die Casting
by Nice Rapid | Mar 01,2021 | Pressure Die Casting

Pressure Die Casting is the best, if not the only, process to create aluminum and zinc products. Many industries need products based on these two materials, and the expertise of any workshop to deliver work based on this it's a deal-breaker for many. This manufacturing method works by high pressures to compress the molten metal into a cast of steel until it gets solid and ready for ejection. As with most manufacturing techniques, there are pros and cons to working with it, and we are going to lay them out in the open for you.

Pros – Benefits and Advantages

  • Pressure Die Casting is the way to go for large volume orders of components. As long as the cast is done according to the specs, you'll precisely get what you are asking for.
  • The production cycles are short, efficient, and cost-effective. The molten metals used for this manufacturing process cools off in seconds when compared with other substances.
  • It's the best manufacturing technique to create thin-walled products. This thickness can be achieved to levels as low as 1mm of surface, accounting for the product's size.
  • Pressure Die Casting is very efficient in creating lightweight products given the sheer precision of the pressure level that can be handled via software.
  • The finished surfaces are smooth as silk. There is no way to sugarcoat this one particular trait since no other manufacturing method can you the finished results pressure die casting offers. There is no need for sanding, and it's ready to receive any coatings you might want to apply.

Cons – Handicaps and Disadvantages

  • You will have to deal with a lot of porosity if you don't keep a clean mold chamber. It's uncertain how many times you would have to do proper maintenance since this varies from project to project.
  • If porosity becomes a significant issue, you will not heat-treat the finished pieces to make the heat disappear since you'll blister the surface and ruin the product you are trying to salvage.
  • The setup cost of Pressure Die Casting is high, especially if you haven't tooled a prototype. While many workshops will create all sections of the product in-house for you, this will add up to the final invoice for the shipment.
  • The mold can be used for a very long time, but if the design is too intricate, continuous maintenance will shorten its lifespan.

So, Can I Work with Pressure Die Casting for My Project?

We can't advise against it, but it requires many factors to be taken into consideration before working with this process. It also factors the workshop you are choosing to work with since many people out there have no idea how to deal with proper surface calculation and locking strength for the required machining. You also have to consider someone who knows how to mitigate restrictions for your project since anything that goes over 530 tons will be ruined. Do your homework and ask questions. It's the only way to make sure everything goes well for you in the end.

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