Gravity Die Casting

Gravity die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. It is accomplished by gently pouring molten metal into re usable metal dies under the force of gravity. The term "die casting" is also used to describe the finished part.

To begin the process a cast iron mould capable of producing tens of thousands of castings must be made in at least two sections to permit removal of castings. These sections are mounted securely to a solid base and are arranged so that one is stationary (fixed die half) while the other is moveable (ejector die half).

To begin the casting cycle, the die caster clamps the two die halves tightly together. Molten metal is poured into the die cavity where it solidifies quickly. The die halves are drawn apart and the casting is ejected. Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting.

The main advantage of gravity die casting over sand casting is the high speed of production. The reusable die tooling allows for many hundreds of castings to be produced in a day. High definition parts reduce machining costs and superior surface finish reduces finishing costs.

Advantages

• Good dimensional accuracy
• Smoother cast surface finish than sand casting
• Improved mechanical properties compared to sand casting.
• Thinner walls can be cast compared to sand casting
• Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
• Steel pins and inserts can be cast into the part
• Faster production times compared to other processes.
• Once the tooling is proven, the product quality is very repeatable.
• Outsourced Tooling setup costs can be lower than UK sand casting.

Although die-castings are in most cases cheaper than sand castings, die tooling is considerably more expensive than sand tooling so an optimum number of castings need to be produced to make the process cost effective in the long run.

We have a wealth of experience in the die casting process and will offer our expertise in satisfying your individual needs. We provide a complete service from design and manufacture of die tooling to final delivery of castings.