Die casting design is a process that demands skill and experience. Therefore, if you are interested in using die casting for your metal fabrication work, you should consult a professional in the field. A qualified manufacturer will help you create a design which meets your demands. In addition, you can discuss the best options for reducing costs. However, if you would like to be involved directly, you can create drafts outlining your requirements. Here are simple guidelines for designing for die casting and avoiding mistakes.
Design for Uniformity
One of the common mistakes that can compromise your fabricated product is significantly varied sections. In simple terms, if you design a metal part or item with sections or walls of different thicknesses, the results might not be ideal. The created product will be compromised by stress concentration. Therefore, you should always aim to keep the designed sections uniform. When variations are demanded for the sake of functionality, you should opt for a gradual transition between walls of different thicknesses.
Plan for Removal
You should think about the removal of your die cast products after fabrication. If the part or item is poorly designed and unsuitable for smooth withdrawal, it will remain stuck in the mould after the molten metal cools down. Ideally, you should avoid unnecessary projections in the design, and the shape of the product should be as simple as possible. In addition, you should ensure that the side walls are somewhat tapered to facilitate quick removal.
You should not plan on designing a metal product that matches the ideal dimensions if the perfection is not essential. In simple terms, you should not specify a close tolerance on your draft if it is not crucial to the functionality of the part. Closer tolerances are more difficult to achieve with die casting. Therefore, there will be higher chances for tighter tolerances. If you are fabricating a general part, you can simply note down the measurement without the tolerance.
Think about Finishing
You should determine the best finishing method during the design process. This practice is important because it will help you visualise the parts and make adjustments. In addition, some finishes can be incorporated into the die mould. For instance, if you want a textured product, you can have your fabricator create a mould with internal texturing instead of paying for secondary finishing. You should compare finishing options such as abrasive blasting, polishing buffing and industrial etching with your needs before making a decision.