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Die casting produces lightweight, high-strength components essential for aerospace applications. These parts meet stringent quality and performance standards for both commercial and military aircraft.

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<h1>All About Surface Finishes</h1><p>Now that you have your casting design, you’re starting to think about surface finishes options. If you don’t know what questions to ask, choosing a surface finish or plating could get tricky. We have compiled a run-through of factors to take into consideration when selecting a surface finish as well as different surface finish characteristics.</p><h2>Do I need a surface finish?</h2><p>While most castings do require a surface finish, it is not always necessary.</p><p>There have been advancements in alloys that have allowed us to provide raw castings where a finish would normally have been required. For instance, when casting an aluminum 380 alloy, traditionally you would normally have wanted a chem film or anodizing for corrosion resistance. With the advent of K-Alloy, we’ve been able to provide parts without an additional finish that meet or exceed the requirements of the customer’s original intent, therefore saving them a lot of money. There have been advancements in zinc alloys as well.</p><p>While these advancements have greatly improved our casting processes, they’re  not necessarily applicable to each particular application. We suggest talking with your die cast manufacturer or asking an engineer for more information on raw castings.</p><h2>Discovery phase</h2><p>After you have decided that your part does need a surface finish, it is important to walk through what we call the “discovery phase.” Here we highlight important aspects that you need to consider in terms of your part design, the functionality of the part, and some price considerations. These are some useful questions to ask yourself when narrowing down your finish options:</p><ul><li>Do I need a decorative finish?</li><li>Do I need enhanced corrosion protection?</li><li>Do I need enhanced wear properties on the substrate?</li><li>Do I need a 100% leak-proof casting?</li></ul><h2>Die casting process control</h2><p>After you’ve spoken with your design and engineering team to determine what surface finish is best for your project, your next consideration is process control. In many cases, the performance of your chosen finish is dependent on the quality of the substrate or the casting. Over the years, we have found that there are key process parameters that need to be monitored during the die cast process. When choosing a die casting company, you need to have a conversation about how they plan on monitoring process parameters. If you have control of your process and you’re monitoring it appropriately, you’re manufacturing quality into the component. <br />It is important to note that the process is more than just die casting. The process begins with a tool design based on the part manufacturability and tool construction. Because of this, you want to get your die caster involved as early as possible so that the part is designed with things like mold flow analysis and construction in mind.</p><p><strong>For more details on surface finish prep, including surface cleanliness, deburring, vibratory shot blasting, download our full on-demand seminar.</strong></p><h2>Popular die casting surface finishes</h2><p>While there are <em>many </em>different surface finishes available and more that are invented daily, we cover the most popular surface finishes and some notable takeaways below:</p><h3>Anodizing:</h3><p>Non-conductive protective coating that seals the part. Comes in a variety of colors including red, blue and black. This is a very affordable option to create durability and corrosion resistance.</p><h3>Chromate:</h3><p>Non-conductive protective coating that seals the part. Comes in a variety of colors including red, blue and black. This is a very affordable option to create durability and corrosion resistance.</p><h3>E-Coat:</h3><p>Racked process, adding more cost in the racking and un-racking process. You get really great coverage with e-coat. It is often used on its own but can also be used as an undercoat for subsequent coatings like a powder coat. Traditionally more functional than decorative, though Dynacast has been successful in providing decorative components using e-coat.</p><h3>Black Oxide:</h3><p>Primarily used on ferrous metals—also copper. You see this a lot on firearms because of its uniform black finish. There is no dimensional change with this coating and it is resistant to peeling and chipping. It provides some corrosion resistance and acts as an excellent vehicle to absorb oils and waxes.</p><h3>Powder Coat:</h3><p>One of the most popular finishes. It’s cured at higher temperatures so it is a tougher finish. Generally, scratch and ding resistant. Available in different colors, gloss levels, and textures. Given that is it cured at higher temperatures, it is important to have a very controlled die casting process.</p><h3>Chrome Plated:</h3><p>One of the more expensive finishes due to the amount of labor involved in chrome plating. Provides a mirror-like finish. There is bright chrome that is used quite a bit in the automotive industry. As well as satin chrome that creates a pearlescent look. 1,000+ salt spray hours so it is great for exterior parts.</p><h3>Bright Nickel:</h3><p>Applied over copper and under chrome for a decorative finish, this plating is fairly brittle, making it unsuitable for parts that may be bent or crimped after plating.</p><h3>Chem Film: </h3><p>Used on aluminum die castings, this finish differs from anodizing by being electrically conductive. As a conversion finish, it does not result in plating buildup. It can be applied through a dipped process, spray, or brush, with dipping being the most common method.</p><h3>Copper-nickel-tin:</h3><p>Utilized to provide solderability to the base metal substrate. There is a matte tin that generally has better solderability, but bright tin is specified more because of its appearance.</p><h3>Cobalt tin:</h3><p>Not quite as expensive as chrome finishes, but it is a racked process. Instead of getting the copper-nickel-chrome, it is a bright nickel with a flash of cobalt-tin. It actually looks similar to bright chrome, but it’s less expensive and it has very good corrosion resistance and wear properties.</p><h3>Electroless nickel: </h3><p>Unique because the nickel is not applied via electrolysis but is instead submerged in a bath, resulting in very uniform plating thickness. The process offers low-phos, mid-phos, and high-phos options, with the phosphorus content in the bath determining the nickel's density. Lower phosphate content provides excellent wear properties, though the finish tends to be brittle, while higher phosphate content results in a more ductile finish.</p><h3>Gold plating:</h3><p>Doesn’t oxidize and it retains its connectivity and solderability at normal temperatures. Used primarily in the electronics industry for connectors, printed circuits, transistors, and integrated circuits—anywhere where contact resistance, solderability, or wire bonding is crucial. The excellent physical and chemical properties of it can offset the whole price of the gold. More expensive, but depending on the application it’s money well spent.</p><h3>Silver: </h3><p>Low cost but it’s susceptible to tarnish when exposed to the atmosphere. It is somewhat of a decorative finish but it has the highest electrical and thermal connectivity of any metal, so it’s highly ductile, malleable, and solderable.</p><h3>Nickel-Free Coating:</h3><p>Hypoallergenic finish. Great for consumer electronics and wearables. We have a whole A hypoallergenic finish that is ideal for consumer electronics and wearables. </p><p>Polyurethane paint:</p><p>Long-lasting and intended for exterior use, this paint is slightly thicker, requiring consideration of its mating surfaces. Wet process and water-borne paints are generally very durable once cured.</p><h3>Impregnation: </h3><p>Seals porosity to create watertight components, offering a highly viable option for improving yields and reducing scrap. Additionally, it is an effective solution after machining, particularly when the "skin" of the casting is removed, to ensure a leak-free component.</p><h3>Teflon:</h3><p>Thermally cured solid film lubricant. Excellent corrosion resistance. Utilizes a rack process.</p><p>For a more in-depth overview of surface finishes, visit the full library of surface finish and plating options—filter by benefit to explore available options for specific project needs. Register below for access to the full on-demand webinar, Surface Finish 101.</p>

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Explore surface finish options for die cast parts, from decorative plating to corrosion resistance, tailored to your performance needs.

Die Casting Surface Finishes | Dynacast Guide

This blog provides an overview of the key factors to consider when selecting surface finishes for die-cast parts, along with a breakdown of popular surface finish options and their characteristics. 

All About Surface Finishes

<p>In today's business landscape, sustainability has transcended buzzword status; it's now a fundamental commitment across industries. Zinc, with its remarkable recycling rate ranging from 70% to an impressive 90%, has emerged as a significant contributor to sustainable die casting practices. This translates into the recycling of 70 to 90 tons of zinc for every 100 tons produced, highlighting its pivotal role in promoting a circular economy. <strong>Zinc is an excellent metal for recycling because the quality of recycled zinc is the same as that of primary zinc, meaning that it can be used to make the same products.</strong> This is because zinc is a pure metal and does not degrade when recycled. </p><h2>The Sustainable Path of Zinc Renewal for Die Casting</h2><p>The journey of zinc from discarded material to a valuable resource for die casting is a carefully orchestrated process.</p><p>It starts with collecting zinc-containing materials like galvanized steel, zinc alloys, and zinc oxide. Once considered waste, these materials now form the foundation of sustainable die casting.</p><p>To achieve the necessary purity for manufacturing, precision pretreatment eliminates impurities like lead, tin, and nickel, ensuring that recycled zinc meets the highest standards for crafting top-quality metal parts.</p><p>Pretreated materials transform within the melting furnace, emerging as molten zinc, setting the stage for shaping metal parts.</p><p>With precision, molten zinc is expertly shaped into ingots or molds that meet specific die casting requirements. This showcases zinc's remarkable adaptability in sustainable die casting, even within recycling.</p><h2>The Benefits of Recycled Zinc for Manufacturing Metal Parts</h2><ul><li><strong>Quality and Performance:</strong> Recycled zinc maintains the same high-quality standards as its primary counterpart. It preserves structural integrity, ensuring that the metal parts manufactured through die casting are of exceptional quality and performance.</li><li><strong>Cost Efficiency:</strong> Die casting with recycled zinc benefits both the environment and your bottom line. Reduced water consumption, lower energy costs, and efficient zinc transportation all contribute to cost savings in metal part production through die casting.</li><li><strong>Customizability:</strong> Recycled zinc is incredibly versatile, allowing for the production of metal parts tailored to your exact die casting specifications. This adaptability provides die casting manufacturers with a wide range of design possibilities.</li><li><strong>Sustainability:</strong> Choosing recycled zinc in your die casting process aligns with sustainability goals. It significantly reduces water usage, curtails the need for additional mining, and minimizes the environmental footprint associated with die casting metal parts.</li></ul>

Discover the sustainability and performance benefits of using recycled zinc in die cast components without sacrificing quality.

Benefits of Recycled Zinc in Die Casting

Recycled zinc is a key player in sustainable die casting, offering high-quality metal parts, cost efficiency, and a reduced environmental footprint by maintaining its quality through recycling and supporting a circular economy. 

Benefits of Recycled Zinc

<h3>Design For Manufacturing Success</h3><p>Musculoskeletal disorders on the job cost employers $50 billion annually. But there are some jobs—even entire industries—in which machines just can’t perform as well as a highly trained, real-life person. Levitate Technologies set out to create a solution for professionals whose work requires constant shoulder mobility. In the process, and with the help of Dynacast, they ushered in the new age of worker safety and productivity: exoskeleton technology.</p><h4>Repeat Performance</h4><p>From automotive plants to manufacturing lines, millions of professionals work with their arms elevated, in a static position, or performing a repetitive motion for long periods of time.</p><p>To reduce fatigue and injury, companies provide ergonomic solutions like braces and stands; but until recently there has been no truly supportive solution for the shoulder joint. The consequences: skilled professionals who injure themselves or age out of a career too soon.</p><h4>Providing a Helping Hand</h4><p>“It’s a problem out there, and it’s a very costly problem,” says Joseph Zawaideh, VP of Marketing &amp; Business Development at Levitate Technologies. “Anything you can do to relieve fatigue, to reduce injury, to make workers happier is a welcome solution that manufacturers are very interested in exploring.”</p><p>It was that goal of reducing worker fatigue, physical burnout, and injury, while not intruding on the workspace that drove Levitate founder, President &amp; CEO, Mark Doyle to develop the innovative designs for what would become the AirframeTM. The Levitate team worked with the new production introduction team at Pathway NPI in San Diego, CA, to engineer and manufacture the technology.</p><h3>A Welcome Relief</h3><p>In his vision, a sleek, lightweight upper body exoskeleton could transfer part of the weight of the arm off of the wearer’s shoulder, neck, and upper back and disperse it safely to the core body—greatly reducing the risk of injury and muscle weakness.</p><p>To accomplish this and keep the wearer’s workspace clear of obstructions, the exoskeleton would need to utilize the most precise ergonomic technology, and be made as light and convenient to wear as possible.</p><p>Importantly, the AirframeTM would have to be manufacturable in quantities that companies around the globe could procure to protect and enable their employees. This critical factor narrowed the field of outsource manufacturers that Levitate could engage, and Mark went to great lengths to find the right one to choose for a partner.</p><p>“They had to be the best of the best,” says Mark, “because we’re going to be making tens of thousands of these devices. Workers around the world are going to be applying pressure on them all day long. Only a company like Dynacast can really provide that level of precision with that level of load management.”</p><h3>Design for Manufacturability</h3><p>Dynacast’s engineers helped ensure the quality, rigidity, and performance of Levitate’s new exoskeleton technology through a series of comprehensive design for manufacturability (DFM) sessions over several months.</p><p>“Before Dynacast, Levitate had not done any of the design for manufacturability work. In fact, all of DFM was driven by Dynacast,” says Mark.</p><p>This was crucial, specifically because the shoulders of the Airframe™ include cassettes filled with tiny components that essentially drive the device and disperse the weight to the core body.</p><p>“The components have to be very rigid and withstand the load, but they also have to be ultralight at the same time. It’s almost like a surgical instrument level of accuracy, but body worn,” says Joseph.</p><p>Dynacast’s engineers solved tricky tolerance, width, and size issues and ultimately specified die cast processes, both for the zinc parts—making them exceedingly durable—and for aluminum, making it incredibly lightweight.</p><h3>Removing the Burden</h3><p>“The final prototype that Dynacast helped us build is in the hands of real users wearing it in real plants,” says Joseph. And the feedback from global companies working with those prototypes? “’We want to order more.’”</p><p>Exoskeleton technology is on the rise as more companies realize its potential as a solution to worker safety, opening Levitate up to new competition. But, thanks to its patented designs and Dynacast’s commitment to its development, it can be manufactured three times lighter than any other exoskeleton currently in production.</p><p>“We engineer solutions. We always want to get involved very early-on with a program so we can engineer the best components and be part of the solution.” – Dan Taylor, Dynacast</p>

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Learn how design for manufacturing (DFM) principles improve part quality, efficiency, and cost control.

Design for Manufacturing: How to Ensure Success

Explore how Dynacast's expertise in zinc die casting and superior plating solutions delivered stunning, uniform brass finishes for a high-profile café counter project, showcasing the versatility and aesthetic potential of metal tiles.

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