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1/16/2024
Transformation of the drives
Die casting process
Expert voices
Why die casting is becoming a disruptive technology
The term ‘disruptor’ is normally associated with tech start-ups or niche operators flying in the face of tradition. It’s not a term you’d necessarily link to a centuries old, highly mainstream industrial process. Perhaps it should be.
Die casting may have been around since the 1830s, but we now face such a unique set of economic, environmental, and societal circumstances, that die casters who respond the right way - leveraging the wealth of new technologies and digital solutions at their disposal - have a very real opportunity. Not only to disrupt an industry. But to change our world. And grow their business in the process.
That’s one big change. But it’s not the only one affecting die casters. You also have increasing raw material and energy costs, the pressure to demonstrate reduced emissions and energy efficient processes, plus a distinct skills shortage/recruitment issue in the die casting industry.
These factors all combine to form a unique challenge and an exciting prospect. Die casters who find ways to produce new types of parts, more sustainably and cost effectively, using less resource (including human resource), will rise to the top. They will become the die casting disruptors best positioned to seize the emerging aluminum opportunity.
Our own machine is a good example. We’ve actually taken things a step further in terms of offering die casters even greater flexibility - a key ingredient for adapting to today’s manufacturing landscape. Its modular design means that whether the need is mass production of smaller electrical components or casting large structural components for electric vehicles, die casters can choose from a range of closing forces and injection units to suit their specific needs.
Better still, modularity means these machines can also be easily adapted should the need arise, for example to accommodate expansion into the production of new/different parts.
Die casters looking for the right machine to support their alu ambitions should also pay close attention to other specific design features and how these contribute to scrap reduction. Less scrap means less wasted raw materials, energy, time, and lower operating costs. Plus of course ‘right-first-time’ high quality castings for faster order fulfilment and end-customer satisfaction.
For instance, does their machine have the rigidity and mechanics to distribute force evenly, preventing distortion? Does it have automated injection control to adapt piston speed based on real time melt flow data, a valuable tool in the fight for uniform casting quality? These are exactly the types of features that help die casters boost performance.
For those adopting new solutions for giant casting applications, it’s especially important to seek the right advice on cell design and equipment integration. In-cell melting, for instance, is a key trend here so be sure to choose a supplier able to offer this as a potential option.
On the digital front, disruptive manufacturing advantage boils down to data utilisation. By visualising data collected from the entire casting process, die casters can quickly spot where process adjustments are needed to produce more good parts, faster and with less downtime. Or at a glance, identify factors affecting cycle times and live production targets. You can’t improve what you don’t know.
AI solutions can take things a step further by actually learning which process parameters produce the best casting quality, and which adjustments have the biggest (and fastest!) impact on scrap reduction. This learnt knowledge is then used to automate control adjustments to achieve optimal results. As part of a continuous process.
The results are lower production costs, lower energy consumption, lower carbon emissions and higher productivity. All of which loop back to that complex mix of challenges modern die casters are facing.
A changing industry needs a new approach
Aluminum is on an amazing growth trajectory. The global market is set to be worth a staggering 277.5 US-Dollar billion by 2030. The shift towards e-mobility is the dominant driver here. By 2035 all cars sold in the EU will need to have zero carbon emissions – with most manufacturers achieving this through electrification, e-fuel vehicles being the exception. Electrification of means bigger, better, lighter parts. New casting designs that consolidate multiple components for reduced weight and simplified assembly.That’s one big change. But it’s not the only one affecting die casters. You also have increasing raw material and energy costs, the pressure to demonstrate reduced emissions and energy efficient processes, plus a distinct skills shortage/recruitment issue in the die casting industry.
These factors all combine to form a unique challenge and an exciting prospect. Die casters who find ways to produce new types of parts, more sustainably and cost effectively, using less resource (including human resource), will rise to the top. They will become the die casting disruptors best positioned to seize the emerging aluminum opportunity.
The die casting tools for a transformative era
So, what exactly are the tools that will help die casters in this mission? Without doubt one of the answers is toggle free die casting technology. The toggle free HPDC machines offer a smaller machine footprint, greater rigidity and fewer wear parts for improved reliability and performance – not to mention lower maintenance costs. They are lighter and leaner to operate (good news for saving energy), while also offering the performance needed to cast an evolving variety of parts.Our own machine is a good example. We’ve actually taken things a step further in terms of offering die casters even greater flexibility - a key ingredient for adapting to today’s manufacturing landscape. Its modular design means that whether the need is mass production of smaller electrical components or casting large structural components for electric vehicles, die casters can choose from a range of closing forces and injection units to suit their specific needs.
Better still, modularity means these machines can also be easily adapted should the need arise, for example to accommodate expansion into the production of new/different parts.
Die casters looking for the right machine to support their alu ambitions should also pay close attention to other specific design features and how these contribute to scrap reduction. Less scrap means less wasted raw materials, energy, time, and lower operating costs. Plus of course ‘right-first-time’ high quality castings for faster order fulfilment and end-customer satisfaction.
For instance, does their machine have the rigidity and mechanics to distribute force evenly, preventing distortion? Does it have automated injection control to adapt piston speed based on real time melt flow data, a valuable tool in the fight for uniform casting quality? These are exactly the types of features that help die casters boost performance.
Automation and digitalisation – a powerful duo
Die casters who leverage advances in automation and digitalisation also stand to gain a number of competitive advantages. From our own experience of providing fully automated cells, we know that seamlessly integrating peripheral equipment and processes supports faster, more efficient production, while also potentially helping die casters overcome recruitment issues and skills shortages. By choosing a fully integrated cell to match layout and production parameters, cycle times can be optimized and reduced to the minimum, maximizing the return of the investment with the best possible TCO.For those adopting new solutions for giant casting applications, it’s especially important to seek the right advice on cell design and equipment integration. In-cell melting, for instance, is a key trend here so be sure to choose a supplier able to offer this as a potential option.
On the digital front, disruptive manufacturing advantage boils down to data utilisation. By visualising data collected from the entire casting process, die casters can quickly spot where process adjustments are needed to produce more good parts, faster and with less downtime. Or at a glance, identify factors affecting cycle times and live production targets. You can’t improve what you don’t know.
AI solutions can take things a step further by actually learning which process parameters produce the best casting quality, and which adjustments have the biggest (and fastest!) impact on scrap reduction. This learnt knowledge is then used to automate control adjustments to achieve optimal results. As part of a continuous process.
The results are lower production costs, lower energy consumption, lower carbon emissions and higher productivity. All of which loop back to that complex mix of challenges modern die casters are facing.
