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Injection molding Applications 6/20/2012
Injection molding is used to create many things such as wire spools, packaging, bottle caps, automotive dashboards, pocket combs, some musical instruments (and parts of them), one-piece chairs and small tables, storage containers, mechanical parts (including gears), and most other plastic products available today. Injection molding is the most common method of part manufacturing. It is ideal for producing high volumes of the same object.[6] Some advantages of injection molding are high production rates, repeatable high tolerances, the ability to use a wide range of materials, low labor cost, minimal scrap losses, and little need to finish parts after molding. Some disadvantages of this process are expensive equipment investment, potentially high running costs, and the need to design moldab......
Die Casting Design 6/20/2012
Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is critical that designers collaborate with the die caster at an early stage of the product design and development. Consulting with the die caster during the design phase will help resolve issues affecting tooling and production, while identifying the various trade-offs that could affect overall costs. For instance, parts having external undercuts or projections on sidewalls often require dies with slides. Slides increase the cost of the tooling, but may result in reduced metal use, uniform casting wall thickness or other advantages. These savings may offset the cost of tooling, depending upon the production quanti......
Cast metals 6/18/2012
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: ZAMAK; zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.The following is a summary of the advantages of each alloy:   Zinc: the easiest alloy to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.   Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.  Magnesium: the easiest alloy ......
Choosing the Proper Alloy 5/18/2012
Each of the metal alloys available for die casting offer particular advantages for the completed part. Zinc - The easiest alloy to cast, it offers high ductility, high impact strength and is easily plated. Zinc is economical for small parts, has a low melting point and promotes long die life. Aluminum - This alloy is lightweight, while possessing high dimensional stability for complex shapes and thin walls. Aluminum has good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures. Magnesium - The easiest alloy to machine, magnesium has an excellent strength-to-weight ratio and is the lightest alloy commonly die cast. Copper - This alloy possesses high hardness, high corrosion resistance and the highest mechanica......
The Advantages of Die Casting 5/18/2012
Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by specifying die cast parts. High-speed production - Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required. Dimensional accuracy and stability - Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant. Strength and weight - Die cast parts are ......
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