What is Die Casting? A Full Guide to This Key Manufacturing Process

Are you having problems getting the metal parts you need? Do you face long wait times, high costs, or parts that break too soon? These problems can stop your work and cost you money. At Istar Machining, we know these problems hurt your business. When parts don’t fit right or take too long to arrive, you lose time and money. Bad parts can make your products fail and upset your customers. But there’s good news! Die casting might be the answer you need. This guide will show you what die casting is and why it could solve your manufacturing problems.

What is Die Casting?

Die casting is a way to make metal parts by forcing hot metal into a mold under high pressure. The molds (called dies) are made of strong metal that can be used many times. When the hot metal cools, you get a part that is:

• Strong
• Smooth
• The same every time can help finish die cast parts to make them even better!

How Die Casting Works

Die casting is like making cookies, but with hot metal instead of dough:

1. Heat the metal until it melts
2. Push the liquid metal into a mold with high pressure
3. Wait for the metal to get hard
4. Open the mold
5. Take out the new part At Istar Machining, our aluminum CNC machining works with die cast parts to make them perfect.

Types of Die Casting

There are two main types:

1. Hot Chamber Die Casting

• The melting pot is inside the machine
• Good for metals that melt easily (zinc, magnesium)
• Faster but can only use some metals

2. Cold Chamber Die Casting

• The melting happens outside the machine
• Good for aluminum and other metals that need high heat
• Takes more time but works with more kinds of metal Our CNC parts machining can work with both types!

Materials Used in Die Casting

Die casting works with many metals. Here are the most used ones:

Why Choose Die Casting?

Die casting fixes many problems in making parts:

1. Makes Parts Fast

• Makes 70-100 parts per hour with machines
• Much faster than making each part by hand

2. Saves Money

• Tools cost $15,000-$80,000 to set up
• But each part can cost less than $1 (for zinc)
• Great for making lots of the same part

3. Makes Good Parts

• Parts come out the same every time
• Smooth finish
• Strong and long-lasting

4. Good for the Earth

• Uses 95% recycled aluminum
• Saves 95% energy compared to making new aluminum

Die Casting Market Facts

The die casting market is big and growing:

• Worth $76.8 billion in 2023
• Growing by 5.5% each year
• Most die casting happens in Asia (63%)

Who Uses Die Cast Parts?

Many businesses need die cast parts:

1. Cars and trucks (54%)
   • Engine parts
   • Steering wheels
   • Body parts
2. Factories (19%)
   • Machine parts
   • Tools
   • Safety equipment
3. Electronics (16%)
   • Computer cases
   • Phone parts
   • Connectors Istar Machining can help with all these uses through our precision CNC machining services!

Problems with Die Casting (And How to Fix Them)

Die casting is great, but it can have problems:

Problem 1: Air Holes

Fix: Use vacuum die casting to pull air out of the mold.

Problem 2: Parts Stick to Mold

Fix: Use special sprays that make parts come out easy.

Problem 3: Parts Look Different

Fix: Keep the metal at the same heat every time. At Istar Machining, we can help fix these problems with our expert CNC milling services.

New Things in Die Casting

Die casting keeps getting better:

1. Big Parts (Gigacasting)

• Tesla now makes car parts that are super big
• One part instead of 70 small parts
• Saves 40% in costs and makes cars 10% lighter

2. Computers Help Make Better Parts

• Computer programs like Magmasoft cut testing time by 50%
• Shows problems before making real parts

3. Smart Machines

• Machines that check parts while making them
• Find problems 30% faster than people can

How Die Casting and CNC Work Together

Die casting makes parts fast, but sometimes they need more work. That’s where Istar Machining helps:

1. Die casting makes the basic shape
2. CNC machining makes the part perfect
3. This team-up makes parts that are:
   • Fast to make
   • Exact in size
   • Work just right

Picking the Right Die Casting Method

How do you know which die casting way is best? Think about:

1. How many parts you need
2. What metal you want to use
3. How big the parts are
4. How much money you can spend
5. How soon you need the parts Istar Machining can help you pick the best way and finish your parts with our custom CNC machining services.

Real Success Story

A car parts maker had a big problem. They needed 10,000 strong, light parts every month. Hand-making was too slow and too costly. The solution? Die casting with aluminum. They got:

• Parts made 3 times faster
• Costs cut by 30%
• Each part was the same as the next
• Much less waste After die casting, they used Istar Machining’s services to make the parts fit just right.

Die Casting vs. Other Ways to Make Parts

How to Get Started with Die Casting

Want to try die casting? Here’s how:

1. Plan your part – Make a drawing or 3D model
2. Pick your metal – Most use aluminum or zinc
3. Find a good maker – Look for experience and quality
4. Get a price – Ask how much tools and parts will cost
5. Order a test – Make a few parts to check quality
6. Start production – Make all the parts you need Istar Machining can help with steps 3-6 and add CNC finishing to make your parts ready to use!

Why Choose Istar Machining for Your Die Cast Parts

At Istar Machining, we make die cast parts work better with our CNC services:

• Fast turnaround – Get parts when you need them
• High quality – Parts that fit right every time
• Fair prices – Good value for your money
• Expert help – We know how to fix problems
• All-in-one service – From casting to finishing

Final Thoughts

Die casting solves big problems in making metal parts. It’s fast, makes the same part every time, and saves money when making many parts. If you need good metal parts, die casting might be your answer. And when you need those parts finished just right, Istar Machining is here to help. Ready to solve your part problems? Contact Istar Machining today to learn how we can help with die casting and CNC machining together!