Overview of Die Casting and Permanent Mold Casting
Die casting is a casting process in which molten metal is injected into a mold cavity under high pressure, allowing it to cool and solidify. It is particularly suitable for high-volume production and can produce precise and complex parts. It is commonly used with low melting point materials such as aluminum, zinc, and magnesium alloys.
Permanent mold casting involves using metal molds that are durable enough to be used repeatedly. It is ideal for producing medium-volume parts and is especially suited for materials that require high temperature resistance and strength. Its mold life is longer compared to die casting, but the production speed is slower, and it is typically used with metals like copper and aluminum alloys.
Die Casting vs Permanent Mold Casting Comparison Table
| Comparison Factor | Die Casting | Permanent Mold Casting |
|---|---|---|
| Mold Cost | High ($3,000-$100,000, steel molds for high pressure) | Low ($1,000-$30,000, cast iron/steel molds with no extreme pressure requirement) |
| Suitable Order Volume | Best for 100,000+ parts (cost-efficient for large batches) | Best for 500-10,000 parts (low mold cost, suited for medium-to-small batches) |
| Production Speed | Extremely fast (300-800 parts per hour, e.g., smartphone cases) | Slower (50-200 parts per hour, e.g., automotive wheel hubs) |
| Part Complexity | Thin-walled and complex structures (<5mm thick, e.g., laptop heat sinks) | Medium complexity parts (5-50mm thick, e.g., engine blocks) |
| Surface Accuracy | ±0.1mm tolerance (no secondary processing, ready for assembly) | ±0.3mm tolerance (requires minimal post-processing, such as deburring) |
| Material Compatibility | Aluminum, zinc, magnesium alloys (low melting point, e.g., magnesium alloy for smartphone cases) | Aluminum, copper, cast iron (high-temperature, high-strength alloys, e.g., copper valve parts) |
| Heat Treatment | Usually cannot undergo heat treatment directly (tends to cause porosity and cracking, secondary processing required) | Can undergo heat treatment, e.g., brake calipers can be heat-treated for increased strength and hardness |
| Typical Product Examples | Automotive battery boxes, smart lock casings, drone frames | Motorcycle wheel hubs, hydraulic valve bodies, small pump housings |
Frequently Asked Questions
| Question | Die Casting | Permanent Mold Casting |
|---|---|---|
| What is the mold life? | 1. Zinc Alloy: 200,000-1,000,000 cycles (e.g., 500,000 smart lock casings) 2. Aluminum Alloy: 150,000-500,000 cycles (e.g., 1,000,000 drone frames) 3. Magnesium Alloy: 200,000-500,000 cycles (e.g., 50,000 smart wearable shells) | 1. Low Melting Point Metals (e.g., Zinc Alloy): 500,000-1,000,000 cycles 2. Medium Melting Point Metals (e.g., Aluminum Alloy): 200,000-400,000 cycles 3. High Melting Point Metals (e.g., Copper, Steel): 1,000-10,000 cycles |
| Minimum Order Quantity? | Starting from 500 parts (below 500, recommend CNC machining) | Starting from 100 parts (small batch flexibility) |
| Can parts with threads be formed directly? | Yes (e.g., threaded smart lock casing formed in one shot) | Requires post-processing (casting blanks first, then milling threads) |
| What materials are suitable? | Aluminum, Zinc, Magnesium alloys (suitable for high-demand consumer products) | Aluminum, Copper alloys, Cast iron (suitable for high-temperature and high-strength industrial parts) |
| What types of products are suitable? | Precision thin-walled parts (e.g., smart home casings, power tool housings) | Medium complexity parts (e.g., engine brackets, small pump casings) |
| Can they withstand heat treatment? | Generally cannot be heat treated directly, prone to porosity and cracking (secondary processing required) | Can withstand heat treatment, e.g., brake calipers can be heat-treated to enhance strength and hardness |
Notes:
- Zinc Alloy Mold Life: 200,000-1,000,000 cycles, suitable for common consumer-grade products such as smart lock casings and electronic product enclosures.
- Aluminum Alloy Mold Life: 150,000-500,000 cycles, widely used for various consumer-grade and industrial-grade castings, particularly in electronic consumer products and drone frames.
- Magnesium Alloy Mold Life: 200,000-500,000 cycles, commonly used for lightweight consumer products such as smart wearables and sports equipment.
Permanent Mold Casting:
- Suitable for high-temperature or high-strength products. Mold life varies greatly depending on the material. For low melting point metals (e.g., zinc alloy), mold life is longer; for high melting point metals (e.g., copper, steel), mold life is shorter.
Conclusion
Choosing between die casting and permanent mold casting depends on several factors, including production volume, part complexity, material choice, and production lead times. Understanding these differences can help you make the best decision to meet the needs of your project. If you’re unsure which method suits your project, feel free to contact us. We will provide you with a feasibility report and a cost comparison to help you make an informed decision.
To further match your needs with the most suitable process, consider the following:
- Part complexity and material requirements
- Optimal production volume for cost efficiency
- The need for heat treatment or secondary processing
Still unsure which method is best for your project? Reach out to us at Shawn@ygdiecasting.com—we’ll provide a feasibility report and cost comparison within 24 hours.
