Ensure Quality by Implementing Key Improvements From the Start

<p>From the initial concept through the final production, ensuring that the right improvements are implemented in your die casting is crucial for creating a high-quality component.</p>

Chromate

Part Improvement

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By refining parts early in the die casting process, Dynacast helps customers achieve superior product quality.

Die casted parts organized in a shipping box

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Enhanced Product Quality

Proactive part improvement through DFM minimizes the likelihood of defects, ensuring product reliability.

Employee hanging parts for the surface finish to dry

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Reduced Risk of Defects

Early part corrections streamline the production process, reducing lead times to get to market faster.

Blueprint of a metal part designed by a die casting engineer

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Accelerated Time-To-Market

Identifying and addressing potential issues upfront prevents costly rework and scrap.

Metal parts stacked into a shipping container

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Cost Reduction

How Do Part Improvements Drive Project Success?

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Heat check, a common die casting defect caused by thermal imbalances, results in cracking or surface damage. Our engineers optimize coolant flow, fine-tune process parameters, and insulate the mold to effectively dissipate heat to mitigate this defect.

Heat Check

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Counter gas porosity by optimizing part and runner designs to enhance gas venting and prevent entrapment.

Gas Porosity

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To combat soldering, where a thin metal layer forms on the die casting surface from die erosion, we focus on eliminating thick sections and refining gating and runner systems for even metal flow.

Solder

Cracks can be prevented by reducing stress points and improving thermal management. Design for Manufacturing (DFM) techniques can significantly strengthen castings and enhance metal flow, reducing the likelihood of cracks.

Cracks

Dimensional issues can be addressed by adhering to print tolerances, monitoring critical process parameters (CPK), and considering thermal effects, draft, and ejector pin adjustments.

Dimensional

Flash, the excess material escaping between mold halves, is prevented by adjusting machine tonnage, ensuring high tool quality, and optimizing process parameters.

Flash

Shrink porosity is reduced by optimizing casting geometry and managing thermal conditions.

Shrink Porosity

Flow marks, including cold flow and non-fillet defects, are streaks on the casting surface caused by molten metal flow. These are addressed by optimizing part geometry, using flow simulation software for detailed analysis, and implementing real-time process monitoring.

Flow Marks

Our Approach to Defect-Free Production

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<h1>Tool Quality, Tool Maintenance, and Tool Replacement</h1><p>When it comes to being a successful manufacturer, you want to get the most value out of each step of your production process, and it can be tempting to cut corners. Without knowing much about the importance of tooling, some manufacturers can slip into the trap of cutting cost with cheaper molds.</p><p>Great tool design is critical to the overall success of your project. No matter how advanced your die cast machines are, if you cut costs for a cheaper tool, you run the risk of creating mediocre parts, adding costs with unnecessary secondary operations—or worse, complete project failure.</p><p>Sign up for our free on-demand webinar and learn about the importance of quality tooling to see the most ROI on your project, how to properly maintain a tool, and when it’s necessary to replace your die cast mold. In this webinar, we’ll cover</p><ul><li>What makes a quality tool</li><li>Dynacast tool maintenance standards</li><li>Designing to prolong the life of your tool</li><li>And more!</li></ul><p><strong>Fill out the form to sign up for our free on-demand webinar.</strong></p><p></p><p></p>

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Discover how to maintain, replace, and ensure the quality of die casting tools for optimal performance.

Die Casting Tools: Quality and Maintenance Tips

Discover how Design for Manufacturing (DFM) can streamline your design process, reduce component costs, and enhance tool longevity in our on-demand webinar, where we'll explore core DFM concepts, inefficiency elimination, and the benefits of early engineer involvement. 

Die Casting Tools: Quality, Maintenance, Replacement

<h1>A3 Machine Capabilities</h1><p>Dynacast’s machine capabilities are a key factor in our ability to deliver high-quality components. Our proprietary multi-slide technology enables fast cycle times and precision in our A2 machines, as discussed in a previous blog. This blog focuses on another machine type, the A3.</p><h2>A3 SIS</h2><p>The A3 SIS machine was introduced in 2010 and features a reinforced main plate with 28 tons of locking force. It can accommodate a die size up to 160 x 140 mm and a shot weight of up to 180 grams. Using the SIS injection system, the A3 SIS offers faster cycle times and increased cavity capacity compared to traditional machines. This machine excels at filling parts quickly, resulting in improved surface quality and reduced porosity. Its ability to handle four slides plus additional integrated options allows for more complex part designs.</p><h3>A3 MAG SIS</h3><p>The A3 MAG SIS machine shares the A3 SIS’s core specifications but includes a two-chamber melting pot for magnesium alloys. Designed for small, high-quality magnesium parts, this machine eliminates the need for machining and complies with CE safety standards. Similar to the A3 SIS, it offers faster cycle times, better handling of complex parts, and the ability to produce parts with thinner walls and tighter tolerances compared to traditional machines.</p>

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Learn how A3 die casting machines enhance part size flexibility, reduce cycle times, and maintain precision for larger components.

Benefits of A3 Die Casting Machines | Dynacast

Discover how Dynacast's A3 die casting machines deliver superior part quality, faster production, and greater complexity compared to traditional methods. 

Benefits of A3 Die Casting Machines

<p>The rapid growth of a new generation of automobiles is driving new engineering innovations and advancements in technology but it is also creating challenges for automotive designers, engineers, and their suppliers. Strategy no longer comes from just removing and replacing a few steel side panels with aluminum, lightweighting is now a whole-vehicle concept to improve not only fuel economy and emissions but performance and handling. At Dynacast, we understand that finding the balance between design, cost and part performance can be very challenging and we’re here to offer design solutions to fit your needs.</p><h2>Sensitivity to Weight Through Design</h2><p>Our thin-wall aluminum casting capabilities are often the solution to many design engineer’s challenges. We can cast aluminum parts that are almost as lightweight as their magnesium counterparts but offer better physical properties like higher tensile strength and additional finishing options. We find the perfect balance between proper overflow placement and runner system and gate design to offer our customers aluminum castings with walls as thin as 0.5mm.</p><p>Additionally, our engineers offer precise design for manufacturing techniques such as removing the core of a component to make the part lighter. With their die casting expertise, they can predict exactly where to remove unnecessary material without compromising the strength of the component. This technique is used time and time again with any of our die casting alloys.</p><h2>Alloy Dependent</h2><p>While we may excel at thin-wall aluminum, it is not the alloy for every project. Fortunately, we offer a variety of alloys that can best suit your project, rather than having your project meet the restrictions of the alloy—or the die casting manufacturer that offers it. If you’re looking for something that has excellent strength-to-weight ratios with outstanding EMI and RFI shielding, consider casting with magnesium. Perfect for electrical housings and connectors, magnesium has been a choice alloy for automotive designers looking to really cut down on weight. Additionally, the accuracy we can obtain casting zinc makes it a great option for wear resistance. Its structural integrity makes it a perfect fit for automotive safety and electrical components. </p><p><strong>Did you know that many of today’s automotive design engineers are turning to aluminum when thermal management is required?</strong></p><h2>Engineering Horsepower</h2><p>Our best-in-class engineering team not only offers expertise in die casting but has decades of experience designing for the automotive industry and we continue to help our customers realize their design potential through rigorous design for manufacturing strategies. Whether it’s our top of the line software to ensure accuracy for your component’s design, tool, and manufacture, or our predictive engineering methodology to identify possible manufacturing problems, by the time your part goes to full production you can rest assured it is fully optimized for the die casting manufacturing process.</p><h2>Stability in a Global Footprint</h2><p>No project is too large or too geographically dispersed for Dynacast. With 23 plants across 16 countries, our global footprint matches yours. So, while many automotive manufacturers are often plagued with shops that close, our customers can rest easy knowing our process stability goes far beyond our casting accuracy. Our 80-years of manufacturing experience is backed by the customer-focused local service you receive in each region. We understand that trust and relationships are very important in terms of support, delivery, and reliability and we believe that we can deliver on that—our top automotive customers have been with us for over 25 years!  With Dynacast, you can seamlessly launch programs anywhere in the world with minimal risk and lower total costs.</p><h2>Your Automotive Die Cast Manufacturer</h2><p>Through years of building relationships with our automotive customers, we've found that by working together on designs from the very beginning we are able to not only offer the best solutions to new-age challenges but also price more effectively. By recommending the best casting solutions up-front with a variety of alloy options and design techniques, we are able to create a better performing part that will be lighter and more reliable. </p>

Discover how lightweight die cast parts can enhance performance, reduce material costs, and improve overall part efficiency in production.

Lightweight Die Cast Parts | Performance & Efficiency

Explore how balancing lightweighting and part performance with advanced design techniques and alloy options leads to optimized automotive components. 