<p>At Dynacast all of our machines need to meet certain standards. As a machine ages, technologies can become outdated and parts can wear. This blog post will give you an inside look at how we keep our machines up and running, and how we upgrade them to ensure the most up-to-date technology is available for our customers’ manufacturing needs.</p><h2>Why is regular maintenance essential?</h2><p>Regular maintenance is crucial for several reasons. Well-maintained machines operate more reliably, reducing downtime and production disruptions. Up-to-date equipment often offers improved efficiency, leading to higher output and lower costs. Adhering to maintenance schedules helps ensure compliance with industry regulations and safety standards. Upgrading machines allows us to incorporate the latest technologies and stay competitive in the market.</p><h2>How do we handle machine breakdowns?</h2><p>While we strive to prevent breakdowns, we are prepared to address them promptly. Our proactive maintenance programs, coupled with a robust inventory of spare parts, minimize downtime. In the event of a breakdown, we can quickly identify and replace faulty components, ensuring minimal disruption to production.</p><p>Accommodating Special Requests (H3)</p><p>Dynacast is equipped to handle special projects and components. Our specialized tooling and machinery enable us to efficiently produce complex parts and meet unique customer requirements. We can also customize machine programming to accommodate specific functions or tolerances.</p>

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Explore how Dynacast's precision die casting machines deliver superior part quality and efficiency, advancing manufacturing processes.

Precision Die Casting Machines | Precision Meets Progress

Dynacast prioritizes machine maintenance and upgrades to ensure optimal performance, minimize downtime, and deliver high-quality products. 

Precision Meets Progress: Machine Upgrades

<p>When searching for the answer to “How much does a die cast tool cost?” It is important to understand <em>why</em> a good die cast tool costs what it does. Be cautious of die cast manufacturers that offer tools at costs much lower than other die casting companies. Tools or molds, are not cheap and going the cheaper route can and will often lead to more troublesome problems down the road. When it comes to die cast tooling, it is worth investing in the design and maintenance of the tool to ensure its longevity.  </p><h2>Superior Tool Design</h2><p>Great tool design is critical to the overall success of your project. When you have a robust part, you want to make sure that your parts are consistent from the first shot all the way to the last. No matter how advanced your die cast machines are, if you cut costs for a cheaper tool, you run the risk of creating mediocre parts—which can add costs later on with unnecessary secondary operations—or worse complete project failure.</p><h3>Runner Systems&nbsp;</h3><p>At Dynacast, we pay more attention to the details of the design and aim to create a tool that won’t get us, or our clients into a bind during production. Not only is it important to work with experienced designers, but using predictive software, like MAGMA, can help to determine what the runner system should look like, how the part is gated, and where the overflows will be. We could just design one runner and vent system to save cost in engineering, but instead we design several runner systems and run multiple MAGMA integrations to select the best runner option along with the optimal overflow placement. If we can predict where porosity and failure will occur in the part, we can design a tool that will anticipate and correct it on the front end—rather than after the fact, which can be expensive.</p><h3>Cooling Circuits</h3><p>When you are creating a part using molten metal, you need to properly cool the part before removing it from the cavity. Removing the part too soon can change the shape of the part and compromise its structure. Some die casting companies just place a simple cooling circuit in the cavity block to save cost in design and tool manufacturing. At Dynacast, we regulate the temperature with very strategic cooling line placement and coverage. On larger more critical projects, additional time is invested in thermal analysis for cooling line optimization.</p><h3>Tooling Inserts</h3><p>Some manufacturers will just EDM the entire cavity to cut down on costs but our engineers incorporate smaller inserts into the tool design. When we design the tool with smaller shut offs it allows us to make adjustments during production. If a tool is eroding quickly, with every shot a critical feature could be changing. Instead of replacing the entire tool—which adds cost and slow production time—only part of the tool needs to be changed. We can predict which area of the tool will wear faster and make that a removable insert. Our customers receive better dimensional stability at a lower cost because we design our tools to last longer and provide better part-to-part consistency over time. </p><h2>Proper Tool Maintenance</h2><p>No matter how predictive your tool design is, over time metal on metal wears and it is important to make timely repairs. Our engineers can predict how long a tool can and should be used before performing maintenance so that downtime is limited. It is much easier and faster to perform maintenance on a tool than to create a new one due to failure. When your tool is not running, it is carefully cleaned and stored so it is ready to go at the start of your next project. Most of our facilities have an ultrasonic cleaning system in-house.</p><h2>Prolonging the Tool Life</h2><p>It is important to consider the life of the die when designing a tool. If you are making thousands of parts every year and you have to replace your die annually, how much money are you losing in downtime or tool costs? When you work with an experienced die casting manufacturer who can predict the longevity of the tool and design it to last longer, you will save tenfold over time. Proper tool design and maintenance will help to avoid weld repairs that often lead to weld sink and flash.</p><h2>Leader in Die Cast Manufacturing</h2><p>In over 80 years of business, we have built over 300,000 unique dies. Our engineers are constantly pushing the envelope with complex part designs and take pride in the quality of work that we provide. We aim to build dies that efficiently cope with high-volume production. With any die casting project, it is always a good idea to include a die casting engineer during the part design phase—it can translate into major cost savings in both design and production down the road. If you are interested in learning more about our in-house tooling or would like to receive a quote for your next project, contact our engineering team today.</p>

Explore the factors affecting the cost of die cast tools and how to optimize your investment for high-quality, efficient part production.

Cost of Die Cast Tools | Dynacast

A high-quality tool, designed with attention to detail and optimized for production, can save money in the long run by reducing downtime and improving part quality. 

How Much Does a Die Cast Tool Cost?

<p>High pressure die casting is a fast, repeatable process that delivers quality metal components, every time—but only if your component is designed properly. There are many factors that go into a successful design for high-volume manufacturing and our team of engineers helps thousands of customers each year successfully launch new projects.</p><h1>What is Injected Metal Assembly?</h1><p><em>There are many different methods of joining metal and other materials, and depending on your industry, there certain considerations that determine the most effective method of assembly. If you’re currently crimping, soldering, staking, or welding components together, injected metal assembly (IMA) could be a more efficient and reliable option for you.</em><br />What is injected metal assembly?</p><p>The IMA process is a type of Insert Molding that uses a molten zinc alloy to join similar or dissimilar components together and create a singular assembled part that is strong, flash-free, and repeatable. With production rates up to 1,000 parts an hour, IMA adhesion ensures consistent higher quality parts while keeping manufacturing costs low.</p><p><strong>The uneven heating and cooling of the welding process produces brittle joints that are vulnerable to stress. As a result, their fatigue strength is far less than that of components joined by IMA.</strong></p><h3>How does IMA work?</h3><p>First, the components that need to be assembled are placed into the machine in a custom designed casting tool. These custom tools are able to accommodate components of various shapes, sizes, and materials.</p><p>Next, the tool closes and precisely aligns to holds the components in their precise position while the molten alloy is injected into the cavity at the intersection of the components. The alloy—usually zinc for its high strength, dimensional stability, and load-bearing characteristics—solidifies in a fraction of a second and produces a strong, permanent lock between the components. Finally, the tool opens and the assembled part is ejected from the die. The ejected component is flash-free, requires no secondary operations, and is stronger than conventionally joined metal components.</p><p><em>When the zinc alloy is injected, it fills the cavities in the custom tool and hardens to create a permanent bond between the components.</em></p><p>In addition to being high in strength and stability, zinc alloys are predictable in their flow and shrinkage characteristics, enabling our designers to calculate with high accuracy the final dimension of the injected metal joint. This allows for exacting tight tolerances to improve the overall functionality of the part.</p><h3>What is the required volume for the IMA process to be viable?</h3><p>Dynacast is capable of running varied volumes, down to 5,000 pieces a year if need be and up to 3 to 4 million parts per year with the help of automation and robotics. The volume of production is largely dependent upon the needs of the customer.</p><h3>When joining metal and a material like plastic, how do you keep the plastic from melting when it comes in contact with the injected molten metal?</h3><p>With IMA, we are able to hold the die closed for up to a whole second, depending on the fragility of the plastic, and allow the heat to dissipate in the water-cooled tool. In addition to this cooling process, the low melting point of injected metal prevents thermal degradation of the parent materials.</p><h3>Can you prototype an IMA part?</h3><p>Yes. While we cannot create a complete part before production begins, Dynacast can build simple “soft tooling” and create part-specific cavity blocks to insert into the tooling for a low production concept. Dynacast also offers a pull-ahead system where we build the tool to a certain point, and if parts produced are accepted by the customer, we complete the tool.</p><h3>How does IMA reduce cost?</h3><p>IMA reduces cost by cutting production time and eliminating the need for secondary operations. While processes like welding, soldering, and crimping are often very labor intensive, IMA has the potential to be fully automated. When part is ejected, flash-free and permanently bonded, it is ready for use.</p><h3>What are major markets served by the IMA process?</h3><p>The IMA process serves virtually any industry and any application. Automotive, telecommunications, electronic components, hardware and appliances, industrial controls, and military industries often utilize parts crafted by the IMA process.</p><p><strong>Would you like to learn more about the IMA process and practical applications? Fill out the form to download our free webinar!</strong></p>

Discover Dynacast's IMA process—a cost-effective method using molten zinc to join components, enhancing strength and reducing assembly steps.

What Is Injected Metal Assembly? | Dynacast Article

Injected Metal Assembly (IMA) is a high-efficiency manufacturing process that uses molten zinc alloy to permanently join metal components with precision, creating strong, flash-free parts with reduced production costs and enhanced reliability compared to traditional methods like welding and soldering.

What is Injected Metal Assembly?

<h1>All About Surface Finishes</h1><p>Now that you have your casting design, you’re starting to think about surface finishes options. If you don’t know what questions to ask, choosing a surface finish or plating could get tricky. We have compiled a run-through of factors to take into consideration when selecting a surface finish as well as different surface finish characteristics.</p><h2>Do I need a surface finish?</h2><p>While most castings do require a surface finish, it is not always necessary.</p><p>There have been advancements in alloys that have allowed us to provide raw castings where a finish would normally have been required. For instance, when casting an aluminum 380 alloy, traditionally you would normally have wanted a chem film or anodizing for corrosion resistance. With the advent of K-Alloy, we’ve been able to provide parts without an additional finish that meet or exceed the requirements of the customer’s original intent, therefore saving them a lot of money. There have been advancements in zinc alloys as well.</p><p>While these advancements have greatly improved our casting processes, they’re  not necessarily applicable to each particular application. We suggest talking with your die cast manufacturer or asking an engineer for more information on raw castings.</p><h2>Discovery phase</h2><p>After you have decided that your part does need a surface finish, it is important to walk through what we call the “discovery phase.” Here we highlight important aspects that you need to consider in terms of your part design, the functionality of the part, and some price considerations. These are some useful questions to ask yourself when narrowing down your finish options:</p><ul><li>Do I need a decorative finish?</li><li>Do I need enhanced corrosion protection?</li><li>Do I need enhanced wear properties on the substrate?</li><li>Do I need a 100% leak-proof casting?</li></ul><h2>Die casting process control</h2><p>After you’ve spoken with your design and engineering team to determine what surface finish is best for your project, your next consideration is process control. In many cases, the performance of your chosen finish is dependent on the quality of the substrate or the casting. Over the years, we have found that there are key process parameters that need to be monitored during the die cast process. When choosing a die casting company, you need to have a conversation about how they plan on monitoring process parameters. If you have control of your process and you’re monitoring it appropriately, you’re manufacturing quality into the component. <br />It is important to note that the process is more than just die casting. The process begins with a tool design based on the part manufacturability and tool construction. Because of this, you want to get your die caster involved as early as possible so that the part is designed with things like mold flow analysis and construction in mind.</p><p><strong>For more details on surface finish prep, including surface cleanliness, deburring, vibratory shot blasting, download our full on-demand seminar.</strong></p><h2>Popular die casting surface finishes</h2><p>While there are <em>many </em>different surface finishes available and more that are invented daily, we cover the most popular surface finishes and some notable takeaways below:</p><h3>Anodizing:</h3><p>Non-conductive protective coating that seals the part. Comes in a variety of colors including red, blue and black. This is a very affordable option to create durability and corrosion resistance.</p><h3>Chromate:</h3><p>Non-conductive protective coating that seals the part. Comes in a variety of colors including red, blue and black. This is a very affordable option to create durability and corrosion resistance.</p><h3>E-Coat:</h3><p>Racked process, adding more cost in the racking and un-racking process. You get really great coverage with e-coat. It is often used on its own but can also be used as an undercoat for subsequent coatings like a powder coat. Traditionally more functional than decorative, though Dynacast has been successful in providing decorative components using e-coat.</p><h3>Black Oxide:</h3><p>Primarily used on ferrous metals—also copper. You see this a lot on firearms because of its uniform black finish. There is no dimensional change with this coating and it is resistant to peeling and chipping. It provides some corrosion resistance and acts as an excellent vehicle to absorb oils and waxes.</p><h3>Powder Coat:</h3><p>One of the most popular finishes. It’s cured at higher temperatures so it is a tougher finish. Generally, scratch and ding resistant. Available in different colors, gloss levels, and textures. Given that is it cured at higher temperatures, it is important to have a very controlled die casting process.</p><h3>Chrome Plated:</h3><p>One of the more expensive finishes due to the amount of labor involved in chrome plating. Provides a mirror-like finish. There is bright chrome that is used quite a bit in the automotive industry. As well as satin chrome that creates a pearlescent look. 1,000+ salt spray hours so it is great for exterior parts.</p><h3>Bright Nickel:</h3><p>Applied over copper and under chrome for a decorative finish, this plating is fairly brittle, making it unsuitable for parts that may be bent or crimped after plating.</p><h3>Chem Film: </h3><p>Used on aluminum die castings, this finish differs from anodizing by being electrically conductive. As a conversion finish, it does not result in plating buildup. It can be applied through a dipped process, spray, or brush, with dipping being the most common method.</p><h3>Copper-nickel-tin:</h3><p>Utilized to provide solderability to the base metal substrate. There is a matte tin that generally has better solderability, but bright tin is specified more because of its appearance.</p><h3>Cobalt tin:</h3><p>Not quite as expensive as chrome finishes, but it is a racked process. Instead of getting the copper-nickel-chrome, it is a bright nickel with a flash of cobalt-tin. It actually looks similar to bright chrome, but it’s less expensive and it has very good corrosion resistance and wear properties.</p><h3>Electroless nickel: </h3><p>Unique because the nickel is not applied via electrolysis but is instead submerged in a bath, resulting in very uniform plating thickness. The process offers low-phos, mid-phos, and high-phos options, with the phosphorus content in the bath determining the nickel's density. Lower phosphate content provides excellent wear properties, though the finish tends to be brittle, while higher phosphate content results in a more ductile finish.</p><h3>Gold plating:</h3><p>Doesn’t oxidize and it retains its connectivity and solderability at normal temperatures. Used primarily in the electronics industry for connectors, printed circuits, transistors, and integrated circuits—anywhere where contact resistance, solderability, or wire bonding is crucial. The excellent physical and chemical properties of it can offset the whole price of the gold. More expensive, but depending on the application it’s money well spent.</p><h3>Silver: </h3><p>Low cost but it’s susceptible to tarnish when exposed to the atmosphere. It is somewhat of a decorative finish but it has the highest electrical and thermal connectivity of any metal, so it’s highly ductile, malleable, and solderable.</p><h3>Nickel-Free Coating:</h3><p>Hypoallergenic finish. Great for consumer electronics and wearables. We have a whole A hypoallergenic finish that is ideal for consumer electronics and wearables. </p><p>Polyurethane paint:</p><p>Long-lasting and intended for exterior use, this paint is slightly thicker, requiring consideration of its mating surfaces. Wet process and water-borne paints are generally very durable once cured.</p><h3>Impregnation: </h3><p>Seals porosity to create watertight components, offering a highly viable option for improving yields and reducing scrap. Additionally, it is an effective solution after machining, particularly when the "skin" of the casting is removed, to ensure a leak-free component.</p><h3>Teflon:</h3><p>Thermally cured solid film lubricant. Excellent corrosion resistance. Utilizes a rack process.</p><p>For a more in-depth overview of surface finishes, visit the full library of surface finish and plating options—filter by benefit to explore available options for specific project needs. Register below for access to the full on-demand webinar, Surface Finish 101.</p>

Explore surface finish options for die cast parts, from decorative plating to corrosion resistance, tailored to your performance needs.

Die Casting Surface Finishes | Dynacast Guide

This blog provides an overview of the key factors to consider when selecting surface finishes for die-cast parts, along with a breakdown of popular surface finish options and their characteristics. 

Precision Meets Progress: Machine Upgrades

Why is regular maintenance essential?

How do we handle machine breakdowns?

Interested in starting your die casting journey?