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Aluminum mold casting design guide

The right design method can significantly enhance your manufacturing experience. If you are a new member of the aluminum mold casting industry, or want to improve your knowledge of die casting design, then this aluminum mold casting design guide is for you. Mechanical engineers and product designers will find this design guide useful. We emphasized important design factors and limitations, which can greatly simplify the aluminum mold casting process, thereby reducing production costs.

Design requirements

When designing aluminum die castings, you must consider its application, appearance, performance, accuracy, and most importantly, cost. First, you must decide what you want to achieve in your part and balance your requirements to match your budget. Here, we emphasized the main things you should pay attention to when designing a section.

Use function

When designing a product, you need to consider its possible applications. Aluminum mold castings can not only play a structural function, but also play a cosmetic function. Therefore, it has become a popular alternative to others.

As modern computers are more powerful than before, the accuracy of mold casting has been significantly increased by multiples. In addition to its superior structural importance, die castings also provide very good cosmetic features.

You should clearly state that your part is applied to mold casters. He can help you choose the right material and determine the appropriate tolerances for the design parameters according to your requirements. You should also consider properties such as corrosion resistance, strength to weight ratio, and electrical conductivity.

But customers often end up paying far more quality and intensity than they need. Therefore, having a good idea about the use of parts will provide you with better insights into the mold casting process.

Appearance requirements

The appearance of the internal aluminum die casting is of little significance. But it is important when it is an external casting part, such as a shell or a shell.

End users are always attractive to beautiful products. Therefore, regardless of the performance of a part, consumers will also give priority to appearance. Therefore, the external die-cast components should have a good appearance.

Therefore, you should design your own parts, keeping the aesthetics in mind. Plan in advance the type of surface finishing you want to achieve. Good finishing can provide extra protection against extreme weather conditions.

Assembly method

The assembly of aluminum mold castings can be relatively simple or highly complex, depending on the complexity of the parts. Traditional mold casting equipment has certain restrictions on the types of castable parts. Therefore, it was difficult to cast parts with complex details.

However, complex parts can be divided into appropriate parts and then connected together after casting by appropriate assembly methods. Some common mold casting assembly techniques include:

Tight
Thread
welding
Injection metal assembly

Core hole and so on.
Before you start designing, you must choose a specific assembly technique for your mold casting. Because the assembly method will seriously affect the design. Choose the appropriate assembly options that meet your requirements.

Cost budget

You should conduct a detailed cost budget analysis of the project. Because budget issues directly affect each of your manufacturing operations. Your design must be completed accordingly to meet your budget.

Experienced designers can greatly reduce mold casting costs without affecting the quality of your parts. You should follow certain design parameters to avoid over-designing parts and ultimately incurring unnecessary costs.

For example, adding pockets allows you to design lighter parts without sacrificing performance. It allows you to reduce material costs. Then reducing or eliminating undercuts and sharp corners can greatly reduce the cost and difficulty of mold and casting.

Product structure design

Properly designing aluminum die castings can bring many challenges. Even the smallest features in the design can have a major impact on casting operations. Therefore, every detail should be appropriately designed in accordance with the recommended guidelines.

We focus on the main features of aluminum mold casting design. You will discover the recommended accuracy of many important functions and understand the design considerations you should follow in the product design process.

Material selection

Product design may vary due to material selection. There are certain restrictions on each alloy. The optimal integrity and strength of aluminum die castings requires careful design and execution.

According to the composition of the alloying elements used in aluminum, its weight, fluidity, strength, conductivity, melting point and other characteristics may vary. But not all materials are suitable as mold casting materials.

Some popular aluminum alloys that you can use for mold casting include,

A 380
A383 (ADC12)
A413
There are many other aluminum alloys available. You must choose the right aluminum alloy according to your requirements and budget constraints.