Die Casting Mold Manufacturing for Superior Repeatability

Mold Manufacturing Processes

Die casting is a manufacturing process that is commonly used for producing accurately dimensioned, sharply defined, smooth, or textured surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The die casting molds process follows the subsequent procedures regarding die cast mold manufacturing:

1. A mold is created in at least two sections to allow the proper removal of the casting.
2. The sections are mounted securely within the machine and are arranged so that one is stationary while the other is moveable.
3. The two are tightly clamped together.
4. Molten metal is injected into the die cavity where it quickly solidifies.
5. The die halves are drawn apart and the casting is ejected.

When compared with sand or permanent mold processes, HPDC (High Pressure Die Casting) is the fastest method in the industry for producing highly precise non-ferrous metal parts.

High Pressure Die Casting Mold Benefits

There are numerous advantages regarding the usage of die casting (or HPDC) process. At Ustar Die Casting, we can provide you with die cast molds that match your design specifications. Some of the advantages and disadvantages of the HPDC molds process include the following:

HPDC Mold Advantages

• Net shape part configuration is achievable
• High dimensional accuracy is achievable
• Fast production
• Thinner walls are achievable when compared to investment and sand castings
• Wide range of possible shapes
• External threads can be casted
• Steel inserts can be over-molded
• Holes can be cored to internal tap drill size

HPDC Mold Disadvantages

• A relatively large production volume is required to make the process cost-effective. (However, SKS would work with customers ways to mitigate this shortcoming.)
• High initial cost (tool, set up)
• Minimum wall thickness: 0.040"
• Maximum wall thickness: 0.200". In some cases, acceptable up to 0.50"
• Draft radii and fillets required on the casting
• Potential porosity issue

Mold Materials for Die Casting

Ustar Die Casting and Machining offers die casting dies for aluminum and zinc alloys: P-20, H-11, H-13, Premium Grade H13 (per NADCA No.229), Superior Grade H13 (per NADCA No. 229), or other grades as defined in NADCA No. 229. Additionally, SKS will guarantee 1 million shots tool life for tool making parts from zinc ZAMAK alloys and 100K shots tool life for tooling making parts from aluminum alloys.