3/18/2025 Markets & Industries Report

Solutions for HPDC tools from steel to simulation, near-contour tempering and refurbishing

Discover how die casting manufacturers are achieving breakthrough results with 3D-printed inserts. While active inserts represent just 12% of production costs, they control 100% of operational efficiency. Through optimized cooling channels and innovative design, a €3,000 investment in 3D-printed inserts can generate €45,000 in annual savings while reducing environmental impact. Learn how this revolutionary approach is transforming manufacturing economics through real-world case studies and proven results.

Revolutionary Die Casting: Turn €3,000 Into €45,000 Annual Savings with 3D Printing

Introduction

In the world of die casting, a relatively low part of production costs can control 100% of operational efficiency. This critical component lies in the active inserts used in die casting tools. Through innovative 3D printing technology, manufacturers are now transforming this small cost factor into substantial savings, while simultaneously reducing environmental impact and improving product quality.

Cost structure of a HPDC part (estimated from conversations)

The Hidden Power of Die Insert Technology

Die casting cost structure reveals an interesting pattern: while the complete tool represents a significant investment, the active inserts - the parts that directly contact the molten metal - account for only 12% of total component costs. However, these inserts disproportionately influence the Overall Equipment Effectiveness (OEE) and Total Cost of Ownership (TCO) of the entire operation.

The primary challenge lies in tool failure mechanisms. Approximately 70% of all die casting tools fail due to thermal fatigue cracks, also known as heat checking. Additional failure modes include metal corrosion, soldering, and erosion.

Each of these issues requires specific technological solutions, whether through improved steel quality, better coatings, or enhanced cooling channel design.

Understanding these failure mechanisms is crucial for implementing effective solutions. The relationship between tool lifespan and operating conditions is direct and measurable, making it possible to significantly improve performance through targeted improvements in critical areas.

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Temperature Control: The Game-Changing Innovation

Temperature management represents the cornerstone of die casting tool performance. The relationship is stark: every one-degree Celsius difference in temperature creates three megapascals of additional stress in the tool. This relationship becomes particularly critical when considering the temperature differential between maximum temperature (when aluminum contacts the tool) and the temperature at tool opening after the spraying process.

For example, if conventional water cooling reduces the surface temperature to 20°C while the operating temperature is 180°C, this creates a 160°C differential - translating to nearly 500 megapascals of stress. By maintaining more consistent temperatures through intelligent temperature control concepts, manufacturers can dramatically reduce these stress levels and significantly extend tool life.

3D printing technology enables the creation of optimized cooling channels that would be impossible to manufacture through conventional methods. The design of these cooling channels follows a sophisticated three-stage approach: First, identifying potential problem areas in the tool; second, conducting process simulation; and third, analyzing thermomechanical stresses. This comprehensive analysis determines optimal cooling channel positioning - a critical balance between stress optimization and cooling effectiveness.

The results are remarkable: in one case study, merely changing the cooling channel design while maintaining the same cooling performance and cycle time reduced stress states by 53% and more than doubled the insert's lifespan.This improvement was achieved using the same material and maintaining identical cycle times - the only difference was the optimized stress distribution through strategic cooling channel placement.

Reduced thermal fatigue through more consistent temperatures
Improved cycle times due to optimized cooling
Lower maintenance requirements
Enhanced part quality and reduced scrap rates

Armin Wiedenegger: Managing director at voestalpine additive manufacturing center

From Investment to ROI: Real Success Stories

The most compelling evidence for 3D printing's effectiveness comes from real-world implementations. In one notable case study, a distributor component saw its lifespan increase from 100,000 to 280,000 cycles - a 180% improvement. While the 3D-printed insert cost €3,000 more than conventional alternatives, it generated annual savings of nearly €45,000 through improved efficiency and reduced downtime.

Another success story involves a transmission housing manufacturer who achieved significant scrap reduction through 3D-printed inserts. Working with Druckguss Heidenau, a strategic approach was implemented where only the critical upper section of the insert was 3D printed, while the lower portion remained conventionally milled - a cost-effective hybrid solution. With an additional investment of just €2,000 per insert, the manufacturer achieved a 3.4% reduction in scrap rates. Given their annual production volume of 600,000 parts, this improvement translated to savings of €194,000. After accounting for the additional costs of the 3D-printed inserts, the net annual savings reached €174,000. Moreover, this reduction in scrap production resulted in an environmental benefit of 80 tons of CO2 emissions avoided - demonstrating how targeted technological improvements can deliver both financial and ecological benefits.

The financial benefits extend beyond direct material savings. Reduced cycle times, lower maintenance costs, and improved part quality all contribute to the overall return on investment. These improvements often pay for themselves within months rather than years.

Beyond Savings: Environmental Impact and Future Outlook

The environmental benefits of optimized die casting tools are significant. In one documented case, a single optimization project resulted in an 80-ton reduction in CO2 emissions through decreased scrap rates alone. This improvement came from reducing the energy and material waste associated with rejected parts.

Looking forward, the die casting industry faces both opportunities and challenges in implementing these technologies:

Continued development of specialized materials for 3D printing
Integration of advanced cooling designs with existing processes
Training and workforce development needs
Reducing costs of 3d printed inserts
Scaling successful implementations across different applications

The future of die casting lies in the strategic application of these technologies. While not every insert needs to be 3D printed, identifying and optimizing critical components can deliver outsized returns in both financial and environmental terms.

Conclusion

The revolution in die casting technology demonstrates how targeted investments in critical components can generate extraordinary returns. By focusing on the 12% of costs that control overall efficiency, manufacturers can achieve significant improvements in performance, cost, and environmental impact. As the technology continues to mature (and reduces the cost base), these benefits will likely become even more pronounced, making 3D-printed die casting inserts an increasingly essential tool for competitive manufacturing.