Design for Manufacture (DFM) Tips for Die Cast Parts

1. Die Casting Parts Weight Reduction

The goal is to reduce the volume of material for components in order to save cost and weight in die casting.
The more metal the component contains, the more time it will take to fill the die cavity and to cool the metal
prior to ejection. We can design pockets to make the cross section thinner, and use ribs to strengthen if
necessary. The locations of pockets need to be considered carefully, as they can sometimes cause non-
constant shrinkage, which may affect components' accuracy.
2. Adding Ribs to Die Casting Parts

The designer can add ribs on thin walls die casting to increase component strength. In particular, he will need
to locate the ribs on suitable locations for ejector pins and to assist in metal flow. If possible, the ribs should
include fillets and radii as much as possible to reduce sharp corners and rapid changes in cross sections.
3. Die Casting Parts Shrinkage

All metals will shrink from die casting temperature to room temperature. The theoretical shrinkage is about
0.6%, always toward the nominal center as shown in the picture to the right. The shrinkage permits the casting
to escape from the tooling cavity, but tends to lock it onto any die section that projects into it. The designer can
apply draft into the component to reduce shrinkage.
4. Draft in Die Casting

Draft is the small taper on the cavity sides that helps the die casting component to eject. Surface with draft on it
usually is highly polished. The outer gap will increase 0.017mm per 1mm based on 1 degree. If no draft is
provided the caster has to use some tolerance for draft.
5. Uniform Die Casting Parts Cross Sections
Designer can make the cross sections uniform in order to speed up the metal flow through the die. Otherwise
the sudden wall thickness change will cause turbulence in the die cast metal, and result in porosity.
Furthermore, casting with large difference in cross sections will shrink irregularly.
6. Radii and Fillets in Die Casting Parts

Designer has to avoid sharp corners and rapid change in cross sections. In addition, an inside corner should be
designed with a fillet and the outside corner with a radius as much as possible. Reducing sharp inside corners
can give additional strength to components and can improve the filling. Radii and fillets as small as 0.127mm
can make improvement to components.
7. Surface Finish of Die Casting Parts

Die casting components' surface finish depends on the finish of the tooling itself. Highly polished tooling
surface will result in good surface casting components. The general die casting parts surface roughness are
from 16 to 64 mircoinches. The die caster can easily produce matte finishes, as well as protruded logos and
trademarks.
8. Parting Line and Ejector Pins for Die Casting

The parting line is the plane at which the two halves of the die meet. The designer must think through each part
carefully, as much of the die cast success (or not) will depend on the construction of parting surfaces. The
parting line should be kept as straight or flat as possible in general.
 The ejector pins are the steel bars used to remove the casting component from the tooling. Good tooling maker
will reduce the “visible” marks to minimum. Designer may advise on the appropriate locations of the ejector
pins.
9. Identification Marks of Die Casting Parts

The designer should indicate where identification marks (logos, part numbers, etc.) are allowed. In general the
die caster is tasked with putting the logo or part number. Typically they will also put on cavity number and date
code to track the castings they made. It is easier to put these marks raised rather than recessed on the tooling.
10. Sliders in Die Casting Parts

The designer should try to avoid holes and undercuts that are parallel to the parting line if possible. The so
called “slider” is the side core used to achieve these undercuts and holes. Slides are costly, and the designer
and die caster should work together to simplify the design of castings and avoid using slides.
11. Function Combination of Die Casting Parts

The designer can combine component’s features in one casting and save on handling, storage and assembly
costs. 
 
12. Variations of Die Casting Parts

For similar parts (especially small ones produced at low volume), the designer might consider using
 post machining/treatment, or
 "multiple-inserts" (to change cavity)
to achieve tooling cost savings through shared die cast toolings.
13. Potential Part Cost Savings from Using Multiple-cavity Die Casting Tools
A die casting tool with multiple cavities can save part cost (since one die casting machine cycle can product
multiple parts), but only if
 the additional cavities do not result in having to use larger tonnage (and more-costly-tor-un) die casting
machines (than a signle cavity tool would require), and
 the additional complexity of the multiple cavity tool doe not result in signifcant reduction of yields.
Die Castings FAQ
 1. Can fasteners or hardware be installed on the die casted parts?
2. We are new to the die casting process, where should we start?
3. What information do you need in order to provide an accurate quote? How soon can I get a
quote?
4. How do customers choose the right die casting alloy: magnesium, aluminum, or zinc?
5. How do customers specifiy the color we need painted on the die casted parts?
6. What are your minimum order quantities (MOQ's) for die casting parts?
7. What is magnesium?
Q. Can fasteners or hardware be installed on the die casted parts?
Yes, we can put PEM studs, nuts, Southco fasteners, or hardware like McMaster-Carr components orinserts to
the casted parts.
Q. We are new to the die casting process, where should we start?
You can start by providing the part's 2D and 3D drawings to us. We can provide Design For Manufacture
(DFM) service for you—plese see our Design for Manufacture Tips for Die Cast Partsarticle.
Q. What information do you need in order to provide an accurate quote? How soon can I get a quote?
Please provide us with the part's 3D CAD drawings (such as IGES, STEP, or X_T). We can also quote based
on 2D drawings (in DWG, DXF, or even PDF format [but with weight information]). We can also import CAD
files directly from popular CAD software, such as Pro/ENGINEER, UGS, Catia, and Solid Edge. In addition, we
need the production information listed in our request for quote form. Quoting turnaorund is typically within a
week, and can be even sooner if there is special timing constraint.
Q. How do customers choose the right die casting alloy: magnesium, aluminum, or zinc?
Magnesium has a density of 1.74 g/cm³, and is the lightest structural metal in common use. Aluminium has a
density of about 2.71 g/cm³, and is the most widely used alloy for castings worldwide. Zinc offers a wide range
of excellent physical and mechanical properties, and can be used to achieve thinner sections in the parts.
Please see the page on material properties .
Q. How do customers specifiy the color we need painted on the die casted parts?
You can specify your color by using RAL or Pantone color codes. If you don’t have the color code, you can
send us a color chip or a color sample for us to come up with a matching color chip.
Q. What are your minmum order quantities (MOQ's) for die casting parts?
Due to our specialty in short run orders, we are very flexible in order quantities. Our quotes always break down
pricing by MOQ's: e.g., there might be a price premium if orders are below 3,000 pcs., and another one if
orders are below 1,500 pcs. (these numbers vary and are just for examples).
Q. What is magnesium?
Magnesium is: among 1) the lightest of all metals (63% of aluminum, 38% of titanium); 2) stronger than
engineering plastics; 3) 100 times better in heat dissipation than plastics; 4) electromagnetic-shielding; 5) best
in vibration absorption of all metals; 6) environmentally safe (non-hazardous and recyclable); 7) easy
to machine; 8) abundant in supply (sixth most abundant on earth).
Die Casting Tooling FAQ
1. What is the tooling material used for your die cast tools? What is the tool life?
2. What are common questions raised during die casting tooling design and tool making reviews
as relate to the part?
3. What are common questions raised during die casting tooling design and tool making
production reviews as relate to the mold?
Q. What is the tooling material used for your die cast tools? What is the tool life?
We use SKD61 (of JIS standard of Japan) tool steel, which provides the same tooling characteristics as those
used in North America, with tool life of 80,000 shots (depending on surface finish requirements).
Q. What are common questions raised during die casting tooling design and tool making reviews as
relate to the part?
Common review questions as relate to the product are whether:
o having enough draft?
o wall thickness is sufficient?
 o parting line is OK?
o needing changeable inserts?
o needing logo?
o if radius is enough?
o if needing to add ribs?
o during final castings:
 date code is needed?
 ejection pin location will affect the part's surface cosmetics?
 if machining will be used (additional material for casting needs to be added for
machining)?
 deciding on parting lines
 deciding on the gating way
Q. What are common questions raised during die casting tooling design and tool making production
reviews as relate to the mold?
They are:
o how many slides will be used?
o how many cavities will be used?
o deciding on the cooling system 
 Plastics Properties
 Below are tables of common plastics materials' properties.
Processing
Item Full Name Density Mechanic Property Applications
Temperature
Acrylonitrile-Butadene- Easy to plating, good compact
ABS 1.07 160-274 °C toy, housing
Styrene resistance
PA Polyamide (Nylon) 1.15 190-350 °C Good toughness and wearing tire, rope
PC Polycarbonate 1.2 220-230 °C Water resistance, climate resistance glass, tube
PE Polyethylene 0.93 80-90 °C Chemical resistance, brittless toy, cable, bag
PP Polypropylene Resin 0.9 100-110 °C Good toughness, Chemical resistance hinge
PVC Polyvinly Chloride 1.38 65-75 °C Cheaper, softer, chemical resistance tank, pipe, shoe
PS Polystyrene 1.05 85-105 °C Good toughness, thermal resistance electronics, toy

  
 Mechanical Properties of Plastics
Tensile Strength Impact Strength( ft- Maximum Minimum Melting Hard-ness
 
(Mpa) lb) Temperature Temperature Point HB
ABS 30 6 80°C -20°C 105°C R110
HDPE 22.1~31.0 N/A 120°C -100°C 130°C SD65
LDPE 8.3~31.4 5 80°C -50°C 120°C SD55
Nylon 6/6 70 1 99°C -70°C° 216°C SD95
PC 60 8 121°C -40°C 121°C R75
POM 60 4 80°C -40°C 160°C R107
PP 31.0~41.4 22.7 135°C 0°C 170°C R95
PVC 45 2 70°C -25°C 80°C R105

