Die Casting Molds. Perhaps the most important tool used in die casting is the different Die Casting Molds used. These molds are responsible in shaping the molten metal which is placed in them. They mold the metal into the desired shape of the manufacturer. But, what is die casting any way?

Die casting is a metalworking process that is best used by manufacturers to create a large quantity of small sized to medium sized parts in a short amount of time. This is done first by melting the metal, usually non ferrous metals such as aluminum, lead, magnesium or zinc among others, then forcing them into the Die Casting Molds. The molds are then machined into dies to create the parts and complete the process.

The machines responsible for machining these molds in dies are known as hot chambered die casting machines and cold chambered die casting machines. The hot chambered machines can accomplish the task with fewer cycles involved in the process; in other words it can accomplish the task faster compared to a cold chambered machine. The latter is used by manufacturers in cases where in the hot chambered machine cannot accommodate the alloy being used. They complete the task slower because the metal needs to be melted in a separate furnace and the time it takes to transfer them into the machine makes the difference.

The Die Casting Molds used in these machines can be rather expensive. They are built from hardened metal and could cost as much as several thousand dollars.

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Die Casting Tooling Molds. The process known as die casting is mainly used in the metalwork industry to create a great number of parts of the same specifications by forcing molten metal which are under high pressure into molds or Die Cast Tooling. This process results in uniform results from most of the products and the finish is smooth and of high quality. The dimensions of each part is almost exactly the same with only about 0.2% difference which means that there is little need for post production clean up or machining.

There are two machines used in die casting, namely the hot chambered die cast machine and the cold chambered die cast machine. Each machine has its own distinct advantages and disadvantages such as the hot chambered die cast machine can finish the product in less time than the cold chambered die cast machine; however there are non ferrous metals that cannot be die casted using the former. Whichever machine a company is using, it is essential that they give some time and thought into the Die Casting Tooling as these are the most crucial tools of the whole process.

Die cast molds or Die Casting Tooling can be very expensive. They are made from hardened steel and they come in different shapes and sizes. Their cost can vary from a couple hundred dollars to several thousand dollars, depending on the size and complexity of the mold. There are single cavity molds and several cavity molds to cater to whatever the manufacturer needs to accomplish.

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How To Save Money When Creating Die Casting Molds. Die casting molds, or simply die casting tooling dies, do not really come as easy as it sounds, and certainly these do not come cheap too. For starters, die casting molds must go through several blueprints in order for these to actually be employed in any type of production. Naturally, blueprints have to be converted to actual dies which could make actual pieces. Even with the best blueprints, only a “finished product” could show the positive and negative qualities of the pieces. In turn, these pieces will have to be scrutinized and tested for both quality and strength. Achieving one “flawless” die design can literally take months of work, and the longer the testing continues, the more expensive it becomes.

Why is this so? Well, most die casting tooling are made from steel alloys, and these do not come cheap at all. So for producers of die cast products, they turn to less expensive alternatives in order to create the prototype of the perfect die. Prototypes are usually made of less dense steel alloys. Although the pieces that are made from these prototypes are made from more solid materials, the prototype dies themselves are usually made of light weight materials. These are also subject to metal erosion when used and cannot be readily modified.

However, the prototypes can be made cheaply, and studied afterwards to note where the flaws in the pieces may emerge. The main purpose of using cheap materials for prototype is simply that: to save money during the designing stage. When the desired “model” is achieved, only then do producers of die cast products use steel alloys to create the dies. However, as part of quality control, the pieces that finally emerge from the steel alloy dies also have to go through rigid testing.

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Die Casting Molds. Aluminum die casting is the method for manufacturers to fulfill orders for large quantities of small to medium sized metal parts. This versatile process has been placed among the highest volume products made by the metalwork industry.

The process of die casting starts off with molten metal. This molten metal is then forced into the Die Casting Molds in a high pressure environment. After which, they are then machined into dies. This process results in the metal parts to be consistent in their dimensions, with high quality and good detail. For most of the time, die casting makes use of non ferrous metals such as tin, aluminum, zinc and copper among others but ferrous metals can also be used in this process. However, harder and stronger metals such as steel and iron cannot be used in this process; instead they are used to make Die Casting Molds.

These die cast molds come in a number of different shapes and sizes. Some can be made as single cavity molds which can make one part for every cycle or multiple cavity molds which can make several parts in a single cycle. Their shape and design would determine the cost of these molds; the more complex the design then the higher the cost of the mold would be. They can be very expensive, ranging from hundreds of dollars to thousands of dollars per mold.

When the molten metal is placed into the Die Casting Mold, they are then placed in either a hot chambered machine or cold chambered machine to complete the process.

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