Step 2: Die casting process

The die casting process is a complex interplay of technology, precision and efficiency. From the sophisticated die-casting machine to the automated periphery to the precise tooling and optimised use of operating materials - every detail contributes to the production of high-quality metal parts. With a focus on sustainability and advancing technology, the die casting process remains a cornerstone of modern manufacturing, constantly evolving to meet industry demands.

The die casting process is a significant step in modern metal processing and enables the production of high-precision components. In this process step, we illuminate the die casting process in detail and take a look at important aspects such as die casting machines, peripherals, tooling and consumables.
Die casting machines are at the heart of the die casting process. They enable the precise shaping of metal parts by injecting molten metal into special die casting moulds. Modern die casting machines are equipped with advanced technology to ensure accurate metering of the metal and high repeatability of the moulding process. This results in consistently high-quality end products.
The peripherals around the die casting machines play a crucial role in process optimisation. Robotic systems take over the removal of the cast parts from the moulds and enable automated further processing. Spraying and temperature control units ensure uniform cooling and temperature control of the moulds, which helps to improve product quality. Post-treatment of die-cast parts is crucial to achieve the desired surface finishes and dimensional accuracy. Peripheral equipment such as deburring tools, grinding machines and CNC machining centres play a crucial role in the finishing of castings. Quality down to the last detail is a key concern in finishing.
Die and tool making is a critical step in the die casting process and is of central importance in producing complex castings. The production of the dies requires high precision and know-how. Modern manufacturing technologies such as CNC machining and spark erosion or EDM (electrical discharge machining) enable the production of highly complex moulds with tight tolerances. Through the use of high-performance materials and modern manufacturing technologies, toolmaking is becoming increasingly precise and durable. 
Additive manufacturing technologies, also known as 3D printing, are revolutionising the die casting process. They enable the production of complex castings without the need for moulds and tools. This leads to shorter development times and enables the production of prototypes and small series with high precision. The use of 3D printing, additionally opens up completely new possibilities in tool making for die casting. This means, for example, that tool designs can be continuously improved to increase the efficiency and quality of the die casting process.
Various operating materials and consumables are used in the die casting process. The choice of the right lubricants and protective materials influences the service life of the tools and the quality of the end products. A sustainable approach such as minimum quantity spraying involves optimising these materials to conserve resources.
Digitalisation is playing an increasingly important role in the die casting process. The networking of machines and systems enables the real-time monitoring and optimisation of processes. Data analysis and artificial intelligence help to increase efficiency and quality.