Die casting is a manufacturing process 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.
Our Die Cast Tools are manufactured to your specification, in line with your budget and warranty requirements using European or Chinese grade steels.
3D tool designs are issued within 4 days of order receipt for approval. We will visit your site to discuss the tool design and make any changes required.
You will receive copies of all documents created throughout the project. Updated tool designs are issued within 48 hours and upon approval we will begin manufacture.
Schedules are issued on a weekly basis with photographs to demonstrate progress. Between 5 & 10 sets of parts are delivered for approval before tools are packed and shipped.
A steel mold, capable of producing tens of thousands of castings in a manufacturing process, is made of at least two sections to permit the extraction of the castings.
The two sections are mounted securely as a fixed die half and an injector die half. The two halves are clamped tightly together and molten metal is injected into the cavity where it solidifies quickly. The die halves are then drawn apart and the casting is ejected.
The Die Casting process is the quickest method of producing accurate non-ferrous metal parts. This is compared to sand casting which requires a new sand mold for each casting and is slower and less precise.
Die casting machines, large or small, vary fundamentally only in the method used to inject molten metal into the die. These are described as either hot or cold chamber die casting machines.
The majority of cast parts are moulded using a non-ferrous alloy such as aluminum or zinc.
Hot Chamber Machines
Hot chamber machines are used for alloys with low melting temperatures, such as zinc, which do not readily attack and erode metal pots, cylinders and plungers. The die cast is immersed in molten metal in a furnace attached to the machine.
Zinc’s superior casting fluidity, strength and stiffness permits the design of thin wall sections for reduced weight and material cost savings.
When a finish is properly selected and applied to cast zinc, almost any desired aesthetic characteristic and coating durability can be achieved.
Cold Chamber Machines
Cold chamber machines are used for alloys with high melting temperatures, such as aluminum.
Cold chamber machines differ from hot chamber machines as the injection plunger and cylinder are not submerged in molten metal. Instead, the molten metal is poured into the cold chamber through a port or pouring slot by a hand or automatic ladle.
In a cold chamber machine, more molten metal is poured into the chamber than is needed to fill the die cavity to helps sustain sufficient pressure to pack the cavity solidly with casting alloy.
European grade steels or domestic equivalents are supplied with either a P20 or S50C mould base.
Our trial machines range from 80 to 400 ton for Zinc and 80 to 800 ton for Aluminium.
Available Materials Include:
Alloy 3: (ZAMAK 3, ZP3, ZL3, ZP0400, ZnAl4, ZDC2)
Alloy 5: (ZAMAK 5, ZP5, ZL5, ZP0410, ZnAl4Cu1, ZDC1)
Alloy 7: (ZAMAK 7, ZL7)
ADC10 (LM24 or A380)
ADC12 (LM2 or A384)
AC3A (LM6 or A413)
enquire about DIE CAST MOULD TOOLS
Die Cast Mould Tool Delivery
Toolcast will transport the mould to your premises and take care of all import duties and taxes.
Sea freight lead-time: 35-40 calendar days door to door.
Air freight lead-time: 7-10 calendar days door to door.
Any warranty issues are managed by Toolcast in one of our partner UK toolrooms.