Five important things in die casting product design

Whether the die casting product design is reasonable or not is crucial to the production and cost of die castings

such as the selection of parting surface, the opening of the inner gate, the launch of the mechanism layout, mould structure and manufacturing difficulty, alloy solidification and shrinkage law, casting precision guarantee, the type of defects, etc., will be die casting itself structure process for the premise of the merits of the structural design of the structural design of the structure is good or bad, a direct impact on the production yields and costs, this paper introduces the die casting Structural design requirements

Key Elements of Rational Die-Cast Product Design:

  1. die casting design reasonable structure and wall thickness:

    An important principle in producing die-cast components is to balance the structure and wall thickness of the parts. Wall thickness affects cooling speed and solidification patterns, thus influencing the final quality of the parts. Uniform wall thickness ensures even cooling, reducing the risk of defects such as hot spots and shrinkage.a, Eliminate internal side concavity; simplify the mould structure, die-casting mould temperature is relatively high, the internal structural parts are easy to expand leading to jamming;
    b, avoid or reduce the core drawing part;
    c, avoid core cross; Reasonable die casting structure can not only simplify the structure of the die casting mould, reduce the manufacturing cost, but also improve the casting quality.

  2. Reasonable mould release angle for die casting design:

    The role of reinforcing bar is the wall thickness is thinned, used to improve the strength and rigidity of the parts, reduce the casting shrinkage deformation, as well as to avoid deformation of the workpiece from the mould when ejecting, filling used to act as an auxiliary circuit (metal flow path);
    Die casting bar thickness should be less than the thickness of the wall, generally take the thickness of the place of 2/3 ~ 3/4, the setting of the reinforcement can increase the strength and rigidity of the parts, while improving the die casting processability. But must pay attention to the following points:
    ① Distribution should be uniform and symmetrical;
    ② and casting connection root to have rounded corners;
    ③ Avoid multiple bar crossings;
    The width of the bar should not exceed the thickness of the wall to which it is connected. When the wall thickness is less than 1.5mm, it is not suitable to use reinforcement;
    ⑤ The mould release slope of the reinforcement should be greater than the casting slope allowed in the casting cavity.

    Minimum mould exit slope reference
    Alloy Type Zn Al Cu
    Inner Cavity Release Slope 0°20’ 0°32’ 0°45’
    Outer surface demoulding slope 0°10’ 0°15’ 0°30’
  3. die casting design – reasonable reinforcement:

    Ribs play a crucial role in enhancing part strength and stiffness without adding excessive weight or affecting the overall design. However, careful positioning of ribs is necessary to avoid deformation due to uneven cooling or the introduction of stress concentrations that may reduce component fatigue resistance.

    The Relationship Between Die-Cast Part Thickness and Reinforcement Ribs
    Wall thickness of die casting(mm) Thickness of reinforcing ribs(mm)
    0.8-2.5 1.5-2.5
    2.0-3.5 2.5-3.5
  4. die casting design – reasonable machining allowance:

    Die casting design should try to avoid machining, machining will increase the cost of parts. Die casting can’t avoid machining, should try to avoid the design of large cutting amount, structural design as much as possible to facilitate the machine or reduce the machine area, reduce the cost of machine. Die casting on the part of the higher dimensional accuracy requirements, die casting process is difficult to meet the requirements, this time it is necessary to carry out subsequent processing, on this part of the structure, the design should try to reserve machining allowance. Die casting surface strength, hardness than the internal high, machining should pay attention to retain the surface of the densification, so the machining allowance can not be excessive allowance, machine plus too much is likely to produce porosity, external surface defects

    Casting size(mm) ≤100 >100~250 > 250 ~400 > 400 ~630 > 630 ~1000
    machining allowance(mm) 0.5-0.1+0.4 0.75-0.2+0.5 1.0-0.3+0.5 1.0-0.4+0.6 2
  5. Rational Design of Surface Treatment for Die-Cast Components:

    The surface treatment of die-cast components significantly determines the product’s aesthetics and functionality, including wear resistance, corrosion resistance, and conductivity. The surface treatment method for die-cast components should be reasonably designed based on different applications to achieve an economical and visually appealing result.

In conclusion, rational die-cast design is crucial to ensuring high-quality products. To achieve success, designers must carefully balance factors ranging from structural properties to surface treatment.


Ningbo Ruiyu Metal Products Co., Ltd. is located in the southern part of Yinzhou District, Ningbo City, Zhejiang Province, China. We are situated 30 kilometers away from Ningbo Port, and our factory covers an area of 3,000 square meters. With a workforce of over 30 employees, our team possesses more than 20 years of experience in the die-casting industry.

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