Miniature die casting is the process of choice to make small and complex parts. Making use of dies and machines that are designed specifically for the production of small parts, the process can be used to produce net shape and flash-free parts.
The process is identical to the hot chamber die cast process that is used to make larger die cast parts. Experts say that the miniature die casting technique is capable of handling tolerances as tight as +/- .001 and wall thickness of 0.020 in die cast parts that weight up to 0.75 lbs.
Some of the important benefits of the miniature die casting process include:
- Flexibility of part size: The part weight can range from 0.10 to 12.0 ounces
- Decreases tooling costs: Getting rid of multi cavity or large single cavity dies can help reduce the tooling cost to minimum
- Can cast net shape parts, flash-free: The process can be used to cast net shape or near net shape parts without the need for any expensive value added operations like flashing after casting
- More dimensional accuracy and capability: The miniature die casting process is capable of maintaining tolerance from piece to piece
- Increased production rates: As the process is fully automated, the manufacturing time and cost is much reduced
- Thin wall die casting: The part weight can be reduce d much without the need to sacrifice mechanical properties
- 5 slide capability: Can be used in the manufacture of complex designs making use of various slides
- Engineering value analysis: The process makes use of engineering techniques to increase manufacturability
Many die casters implement miniature die casting to offer parts of security devices, industrial control units, computer hardware, parts of telecommunication, and other electronic devices. The main advantage of the automated miniature hot chamber zinc die casting is that it can offer process times up to 1200 cycles per hour, and that too, without the need for any secondary deburring or trimming. Another advantage is the use of inexpensive tooling that range in price from 7,500 to 35,000 dollars, which offer very low cost parts.
Miniature die casting tools have long life, and due to the fast cycle times, the part cost can be decreased much and will be a fraction of the conventional die casting costs, making it an excellent process for manufacturing small parts that need good precision.