The following are some basic design guidelines for die castings:

  • Uniform wall thickness.
  • Rounded corners on all edges and corners.
  • Smooth blending and continuity of all features.

Additional design modification suggestions will be provided to ensure your part is cast successfully.

Please provide us with a 3D CAD drawing of the part (e.g. IGES, STEP or X_T). We can also quote from 2D drawings (DWG, DXF or even PDF format [but with weight information]).

We can also import CAD files directly from popular CAD software such as Pro/ENGINEER, UGS, Catia and Solid Edge. in addition, we need the production information listed in the quotation. Quotation turnaround time is usually within one week, or even faster if there are special time constraints.

Because we specialize in short-term orders, we are very flexible with order quantities. Our quotes are always broken down into pricing based on minimum starting quantities: for example, there may be a premium if an order is below 3,000 units, or a premium if an order is below 1,500 units. (These numbers vary and are used as examples only).

Sand casting can be used with a wide range of metals, including iron, aluminum, steel, zinc, brass, and bronze alloys.

Due to its exceptional versatility, sand casting is one of the most widely used manufacturing processes for a variety of applications, including:

  • Construction equipment (housings, combustion chambers, manifolds, gearboxes, drive impellers)
  • Engine components (housings, mounts, frames, pistons, cylinders, manifolds)
  • Wind energy components (torque arms, rotor hubs, blades, shaft pins)
  • Agricultural applications (axles, gears, gearboxes, brake drums, pulleys)

Sand casting uses the following types of sand to produce molds:

  • Greensand. Also known as clay, green sand molds are made using wet sand. The process is fast and efficient, and the sand can be reused.
  • Resin sand. Resin sand is molded by heating, and the surface is smooth when molded, so less finishing work is required.

The die-casting process is usually not well suited for low-volume prototyping. But that doesn’t mean we can’t deliver on the prototyping process. When developing your ideas, we can handle the most efficient prototyping process for your components.

Our sales and design engineers have seen everything from prototyping for the medical, automotive, consumer electronics, aerospace and defense industries, and more. With our experience, we have the ability to help you optimize the prototyping process for any precision metal component.

To expedite your request for quotation, we recommend that you sign our NDA form. We can use your form if necessary, but be aware that it may slow down the RFQ process.

Yes, CCS can use molds from other foundry companies; however, we must evaluate the quality of the tooling before putting it into production to ensure the highest quality parts are available.

The minimum or maximum cross-sectional wall thickness of any part depends heavily on the overall part size and design.

For example, a wall thickness of 0.010″ may be possible if it is localized, but not if it spans the entire length of a 4″ long part. Typically, the optimum wall thickness is 0.040″ to 0.120″, again related to the overall size of the part. Minimizing wall thickness also reduces the material content of the part and its cost.

No, porosity is inherent to the die casting process. However, with proper tool design, porosity can be minimized and positioned in non-critical areas.

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