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Introduction
Aluminum die casting is a highly efficient manufacturing process for producing complex, high-strength, lightweight parts in large volumes. But to get the best results, it’s crucial to design parts correctly for the die casting process from the very beginning.
In this article, we’ll walk you through a practical, customer-oriented Aluminum Die Casting Design Guide — covering essential design tips, common pitfalls to avoid, and key factors to consider when creating your next aluminum die cast part.
📌 What is Aluminum Die Casting?
Aluminum die casting involves forcing molten aluminum under high pressure into a steel mold (die). Once solidified, the part is ejected, providing a highly accurate, smooth-surfaced, and dimensionally stable product.
Common Applications:
- Automotive parts
- Intercooler tanks / CAC tanks
- Electrical housings
- Consumer electronics
- Industrial components
📌 Key Design Considerations for Aluminum Die Casting
If you’re planning to develop a new aluminum die-cast product, consider these critical points during the design stage:
✅ 1️⃣ Wall Thickness
Recommended: 2.5 mm to 4 mm
Why it matters:
Uniform wall thickness reduces the risk of shrinkage, porosity, and warping. Large differences in thickness cause uneven cooling, leading to defects.
Tip: If varying wall thickness is unavoidable, use fillets and gradual transitions to minimize stress concentrations.
✅ 2️⃣ Draft Angles
Recommended: At least 1° to 3° per side
Why it matters:
A draft is a slight taper applied to the walls of the part to allow easy removal from the die without damaging edges or surfaces.
Tip: Add a larger draft for deeper parts or rougher surface finishes.
✅ 3️⃣ Fillets & Radii
Recommended: Minimum fillet radius of 0.5 mm
Why it matters:
Sharp corners can create stress concentrations and cause premature die failure or part cracking. Smooth transitions improve metal flow and part strength.
✅ 4️⃣ Ribs & Bosses
Why it matters:
Ribs are used to increase strength without adding excessive weight. Bosses are used for mounting or assembly points.
Tip:
- Rib thickness should be 50-70% of the adjoining wall.
- Add generous fillets where ribs meet walls.
- Avoid deep, narrow bosses — consider vent holes to release trapped air.
✅ 5️⃣ Holes & Undercuts
Why it matters:
Holes should be designed with a minimum diameter of 1.5 mm and avoid excessive depth. Undercuts increase tooling complexity and cost.
Tip:
If undercuts are necessary, consider adding side cores or slides — but this will increase tooling cost and lead time.
✅ 6️⃣ Surface Finish
Die cast parts typically come out with a fine, smooth surface. However, areas requiring secondary machining or tighter tolerances should be clearly marked in the design.
Tip:
Design flat, unobstructed surfaces where secondary operations (e.g., drilling, tapping) are needed.
✅ 7️⃣ Tolerances
Typical aluminum die casting tolerances:
- Linear dimension: ±0.1 mm for small features
- Flatness: ±0.2 mm over 100 mm
- Hole diameters: ±0.05 mm
Tip:
Discuss tolerances early with your supplier. Tighter tolerances increase costs due to higher scrap rates and extra machining.
📌 How to Reduce Cost in Die Casting Design
- Use uniform wall thickness
- Minimize undercuts and side cores
- Consolidate multiple parts into one casting where possible
- Allow generous draft angles
- Avoid unnecessarily tight tolerances
📌 Common Defects to Avoid in Die Casting
| Defect | Cause | Prevention |
|---|---|---|
| Porosity | Trapped gas or shrinkage | Uniform wall thickness, good venting |
| Warping | Uneven cooling | Consistent wall thickness, balanced design |
| Cold shuts | Metal flow meeting incompletely | Optimize gating and parting lines |
| Flash | Excess metal escaping at die parting line | Proper die clamping, maintenance |
📌 Conclusion
A successful aluminum die casting project starts with a smart, practical design. By following the tips in this guide, you can improve product quality, reduce manufacturing costs, and shorten your lead times.
At [Your Company Name], we help clients optimize their designs for aluminum gravity casting, low pressure casting, and high pressure die casting. Our experienced engineers offer free design-for-casting consultations to help you improve performance and save costs.
📌 Contact Us for Aluminum Casting Support
If you have a new project or need advice on improving an existing part design, reach out to us!
🌐 www.yourcompanywebsite.com
📧 sales@yourcompany.com
📸 Image Suggestions:
- Die Casting Process Illustration: Diagram showing aluminum being injected into a die.
- Draft Angle & Wall Thickness Guide: Simple infographic showing recommended draft angles and wall thicknesses.
- Typical Die Cast Part Image: Photo of an automotive or electronic housing die-cast from aluminum.
- Common Defects Table: Visual table with images of porosity, warping, and flash.
Would you like me to prepare the image descriptions for these now too? Or maybe you’d like this converted into a blog HTML-ready layout? I can do that as well — just let me know! 🚀
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📸 图片建议（配合刚才那篇文章）
① Die Casting Process Illustration
内容描述：
一张简洁示意图，展示铝液通过高压注入模具（Die）腔体的过程。
画面元素：铝液→活塞→模具→冷却→成品取出。
用途：放在“What is Aluminum Die Casting?”段落下面，帮客户直观理解工艺流程。
② Draft Angle & Wall Thickness Guide
内容描述：
一张表格或示意图，列出：
- 推荐壁厚 2.5-4mm
- 推荐拔模斜度 1°-3°
画面元素：简化的立方体或者零件示意，标出壁厚和拔模斜度角度，直观展示设计规范。
用途：放在“Key Design Considerations”里的第1和第2条之后。
③ Typical Die Cast Part Image
内容描述：
一张铝压铸件实物照片，比如汽车发动机盖、电子壳体或散热器。
画面元素：高清铝件表面，最好是带有细节的边缘、孔位和筋位。
用途：放在文章中部或者“Surface Finish”那一节。
④ Common Defects Table
内容描述：
一张图表形式，带图片小图，列出常见缺陷及对应原因：
- Porosity (气孔)
- Warping (变形)
- Cold shuts (冷隔)
- Flash (披锋)
画面元素：每种缺陷配一张小图，右边列上原因和预防方法。
用途：放在“Common Defects to Avoid”表格前面。
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aluminum-die-casting-process.png，利于谷歌图片搜索优化。 - 图片Alt标签写成相关关键词，如
Aluminum die casting process diagram。
如果你想，我还可以帮你直接生成文章HTML排版版本或者写好图片说明，发给美工就能做图。要不要？要的话跟我说一声，我来帮你整理好👌
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📖 Aluminum Die Casting Design Guide
Introduction
Aluminum die casting is one of the most efficient and cost-effective methods for producing complex, lightweight, and high-strength parts in large volumes. A well-planned design is key to avoiding casting defects, reducing production costs, and ensuring consistent product quality.
This guide provides essential design tips, technical considerations, and common mistakes to avoid for your next aluminum die casting project.
📌 What is Aluminum Die Casting?
Aluminum die casting is a manufacturing process where molten aluminum is injected into a steel mold (die) at high pressure. After solidifying, the part is ejected, creating a precise, durable, and repeatable product with a smooth surface.
Typical Applications
- Automotive intercooler tanks / CAC tanks
- Engine covers and brackets
- Industrial equipment housings
- Electronic enclosures
Advantages
- High dimensional accuracy
- Fast production cycle
- Excellent surface finish
- Strong and lightweight parts
📌 Key Design Considerations
✅ Wall Thickness
Recommended Range: 2.5 mm – 4 mm
Uniform wall thickness ensures even cooling, minimizes shrinkage and porosity, and improves mechanical performance.
Tip: Avoid sudden changes in thickness. If necessary, use fillets or ribs to balance transitions.
✅ Draft Angles
Minimum Draft Angle: 1° to 3° per side
A draft allows the part to be easily ejected from the die, reducing the risk of scratches or edge damage.
Tip: Use a larger draft angle for deep or textured surfaces.
✅ Fillets & Radii
Recommended Minimum: 0.5 mm fillet radius
Sharp internal corners increase stress and can cause cracking or early die wear. Smooth transitions improve strength and metal flow.
✅ Ribs & Bosses
| Feature | Recommended Design |
|---|---|
| Rib thickness | 50%-70% of adjoining wall thickness |
| Fillet at rib root | Minimum 0.5 mm |
| Boss height | ≤ 2.5 times its diameter |
Tip: Avoid deep, narrow bosses. Add vent holes for airflow if needed.
✅ Holes & Undercuts
| Feature | Recommendation |
|---|---|
| Minimum hole size | 1.5 mm |
| Avoid deep blind holes | Less than 3 times diameter |
| Undercuts | Avoid or minimize to reduce tooling cost |
✅ Surface Finish
Standard die cast parts have smooth, clean surfaces. Areas requiring secondary machining should be clearly marked in the drawing.
Tip: Avoid placing critical features on parting lines to improve surface quality and dimensional accuracy.
✅ Tolerances
| Feature | Standard Tolerance |
|---|---|
| Linear dimensions | ±0.1 mm (small features) |
| Flatness | ±0.2 mm per 100 mm |
| Hole diameters | ±0.05 mm |
Tip: Tighter tolerances increase cost. Discuss tolerances with your supplier during the design stage.
📌 How to Reduce Die Casting Costs
- Maintain uniform wall thickness
- Avoid undercuts and complex side cores
- Consolidate multiple parts into one casting
- Use generous draft angles
- Avoid unnecessarily tight tolerances
📌 Common Die Casting Defects and Solutions
| Defect | Cause | Prevention |
|---|---|---|
| Porosity | Trapped gas or shrinkage | Uniform wall thickness, good venting |
| Warping | Uneven cooling | Balanced design, even walls |
| Cold shuts | Poor metal flow meeting points | Optimize gating, good fill speed |
| Flash | Excess metal at die parting line | Proper die clamping, regular maintenance |
📌 Conclusion
A successful die casting project starts with a smart, optimized design. Following these practical guidelines improves part quality, reduces cost, and shortens production time.
We offer free design-for-casting consultations to help you optimize your product before tooling begins.
