Typically, die castings parts consist of thin-walled structures, and there are no hard and fast rules for minimum and maximum wall thicknesses. It is important to design uniform walls throughout the parts and where changes occur. This will ensure smooth metal flow during filling and minimize distortion due to cooling and shrinkage. Good mold filling will produce parts with good performance and few defects. The key is to design the casting so that it fills the entire mold before solidification begins. Failure to fill the entire mold first can result in cold segregation (poor surface finish) in the casting. You can reduce the risk of cold traps by using a radius without any sharp or unnecessary corners that would hinder the flow of the melt in the mold.

Innovations in die casting technology have made it possible to produce parts with minimum and maximum thicknesses that were unattainable just a few years ago. Use this feature only if you feel it is necessary to improve performance or achieve economic benefits. Otherwise, stick to a uniform wall thickness. You can get the metal to flow better through molds with thicker walls and ribs. When the main wall has prominent features, make sure they do not significantly increase the thickness of the wall. The excessive volume will delay cooling.

When viewing the part from the mold open direction, make sure that the features protruding from the sidewall do not overlap each other, this will avoid dying casting depressions.

Although design casting allows the production of intricately detailed assemblies, designers should avoid using internal undercuts when designing parts because the moving internal core mechanics are difficult to maneuver. You can produce this feature by machining, which increases part cost but reduces tooling costs by avoiding core pulls in the mold.

NingBo GSK Powder Metallurgy Co., Ltd. is a stamping auto parts manufacturer that manufactures and wholesales Die Casting Parts, MIM-Lock Parts, and more.