From casting to packaging Dynacast Lake Forest’s automated conventional aluminum die cast cell offered our customer a 60% cost-savings compared to the traditional cycle time and handling associated with the additional secondary processing. Watch as this cell creates die cast parts and seamlessly runs them through the entire production process, without the touch of a single hand.

The video starts with an overhead shot of the entire automated process. Utilizing the conventional cold chamber die casting process, the aluminum is first ladled into the machine.

A robot extracts the parts where they are quenched and then transitions them through a dryer to blow off the excess fluid. From there, the parts are moved on to the trim press. Usable materials, such as the biscuit are returned directly back into the furnace and re-melted and cast again. This helps to eliminate scrap and therefore helps to reduce cost The other material is removed and processed externally for recycling.

Dynacast Lake Forest is committed to reducing their carbon footprint.

Next, a double-headed robot picks up and in the same motion, places two new parts on the CNC fixture. An automatic clamp secures the part for machining. Once it has machined the one side it automatically flips over and machines the other side. The parts are then placed on a conveyor where they are immediately fed into the tumble wash utilizing ceramic media to break off any burrs.

The parts are then dried and packaged.

Continuous Flow Manufacturing

Utilizing this continuous flow manufacturing process, we are able to reduce this customer's overall cost by 60% and significantly reduce cycle time by completely eliminating the need for batching. The entire project is monitored including the robots and the conveyors to minimize any downtime—the cell even measures and keeps track of yield rates. Our operations people can monitor this board electronically from anywhere—even on their phones. This ensures we are continuously tracking the cell to make sure we hit our targets.

While the die casting, quench and trim process may look like your typical automated die casting cell, the real value of this operation comes from the machining. In a normal production run, parts would be cast and then sit waiting for someone to take them to the CNC area where parts are put in by hand. Here we eliminate the CNC operator. Additionally, you’re eliminating the person that would then take the parts to the tumble wash and loading them and then someone unloading them. Automating the entire process, you only need one person who takes the parts only after they are put into the box for packaging.

Right Project, Right Volume

This automated cell was created for a specific project so while this is not a typical run for our plant, it is possible. For the right project and the right volume, Dynacast can create automated cells to help customers save money and ensure product flow.  Having the capital to fund this investment is an advantage to working with Dynacast—unlike a typical job shop.

If you have a high-volume project that requires machining, talk to our team today to learn more about our automated die casting cells.