MAS 2.0 - Guides - F.A.Q. - Tutorials - Home

Design Considerations

It is highly recommended to study the overall function of the product and consider the possibility of incorporating several functions into one die casting including integral features for attachment and assembly.

The designer should try to reduce after cast machining as die casting can afford it.

The dies are hardened by heat treatment after being machined. This makes them very unlikely to be modified. Thus, the designer is urged to reach a final design for the die-cast part and check its castability with the die caster before design and construction of the die begins.

Proper casting design, die design, casting procedure and equipment can lead to production of quality die castings. By specifying the tolerances to be as loose as the part permits, excellent dimensional accuracy can be obtained and after-cast machining can be eliminated and reduced.

The ejector-pin location should be specified early in the production design, preferably with the consultation of the die caster.

The continuity of metal flow is disturbed by abrupt section changes, sharp corners, and walls at an acute angle to one another, etc... This promotes porosity and surface irregularities. It is a good design practice to make the radii as large as possible and to blend the differing sections into one another.

Computer-aided design programs and simulation software can help in optimizing materials flow and cooling of the casting in the die.

Source: Bralla, Design for Manufacturing Handbook.