NADCA Design Seminars

Do you design or purchase die castings?Join companies like Alcon Labs, an Eye Surgery Device manufacturer, pictured, in gaining the benefits of a NADCA Design Seminar. Scheduling a NADCA Design seminar on-site at your company is one of the best ways to learn more about the benefits that die casting has to offer your company. The seminar covers topics from development, design, specification,purchasing all the way to manufacturing. Learn more about having a NADCA Design Seminar at your company by visiting: www.diecastingdesign.org/seminars/

Holes and Windows

Holes and windows present a challenge to molten metal flow during filling as well as during ejection of the die casting from the die. However with simple geometry changes and modifications to the die and part holes and windows can be optimized for successful die casting. To learn more about holes and windows in die casting designs please visit: http://www.diecastingdesign.org/design/basic/holes_windows/

holes windows

Aluminum Die Casting Alloy Sources

Have you ever wondered where the aluminum alloys used in die casting come from? Although some aluminum alloys are smelted and refined from raw materials to keep up with increasing demands, most aluminum die casting alloys use recycled scrap as their primary source of material. For more information on the aluminum die casting alloy supplies view the video module at: http://www.diecastingdesign.org/alloys/supply2.htm

audi

Die Castings Perform in Audi Space Frames

Aluminum die castings serve as main components and nodes for body componentsused in the high performance Audi A8 luxury sedan and R8 supercar. Car and Driver recently visited the production lines for both these vehicles to learn more about the construction and assembly for the see advanced vehicles. For more details on how these two cars are manufactured and how die castings play apart visit: http://blog.caranddriver.com/a-stroll-through-audi%E2%80%99s-aluminum-emporium-how-a8s-and-r8s-are-born/

Die Casting Geometry: Ribbing

No, not the grief that you give the person in the cubical next to you… the ribs you add to a part to increase strength using less mass.Being an additive manufacturing process die casting allows ribs to be easily integrated into your next die cast product design.Ribs may also assist in providing metal flow to difficult to fill areas.Although just like ribbing your cubical neighbor ribbing can be over applied.To learn more about ribs for die casting designs please visit: www.diecastingdesign.org/design/basic/ribs/

ribs

HyperCast Materials

The new NADCA Hyper Cast program is currently underway to help lower the costs of implementing aluminum and magnesium metal matrix composites in future die cast product designs. Metal matrix composites (MMC) combine the properties of metals and ceramics into one material.Traditionally the mixing of ceramic particles into metals has been difficult and costly. Hyper Cast technology allows for the introduction of ceramic particles into a molten metal just before it is cast allowing for a significant cost reduction over previous methods.This technology takes advantage of highly exothermic reactions to rapidly create ceramic particles in the aluminum or magnesium melt. Although the focus of this project will be onlight weighting vehicles, other design applications are sure to emerge.For more information on the Hyper Cast project please visit: www.diecasting.org/research/hyper cast/

shaker

Die Casting Top of Sweet Design

Did you know that every time you use a sugar shaker like the one shown here that you are taking advantage of the properties a die casting has to offer?Designer HenryKeck designed this iconic sugar shaker in 1955 and utilized a die cast top to meet his design criteria,to find out the history behind this design and the reasons die casting was selected visit: http://latimesblogs.latimes.com/home_blog/2010/03/back-story-the-men-behind-a-sweet-design-.html

New Mustang Engine Benefits from Die Castings to Cut Weight and Increase Performance

The new 3.7 liter TiVCT V-6 engine for the 2011 Ford Mustang uses a lightweight die cast aluminum cylinder block as well as deep-sump oil pan.Both die cast components help the engine produce more power and torque (305 hp and 280 ft.-lb) while maintaining a fuel economy of 30mpg despite the engines smaller displacement.To read more about the new 2011 Mustang V-6 visit: http://media.ford.com/article_display.cfm?article_id=31278

And to see a video of a ride with the new engine visit: http://www.youtube.com/watch?v=DarlDXmNY_g

Casting Design Seminars at CastExpo’10

The Casting Designer and Buyer Tracks at CastExpo’10 will provide education on topics ranging from the basics of metal casting to casting design conversion and sourcing tips by a lineup of expert speakers.The seminars will be held in the Cast in North America Pavilion where metalcasters (including die casters)will showcase their casting capabilities.This area will allow buyers and designers to network with suppliers and provide an opportunity to discuss design challenges face-to-face with experts.In addition the winning castings from the 2010 International Die Casting Competition will be on display show casing the capabilities of the die casting process.For more information visit: www.diecastingdesign.org/castexpo/

Helpful Bosses

Hopefully you report to a helpful boss at work… for die cast part designs bosses are useful in a different way, often being used for standoff and mounting points for assembly components.Many times a central hole is added to a boss and this hole is often subsequently tapped to add threads without requiring a metal insert as is often needed for plastic parts. To hear learn more about bosses please visit: http://www.diecastingdesign.org/design/basic/bosses/

boss

ZA Die Casting Alloys

Did you know that zinc aluminum alloys, often called ZA alloys, were created to offer improved properties over straight zinc alloys? ZA alloys offer distinct advantages over the zinc alloys, including higher strength, increased wear resistance, improved creep resistance and slightly lower densities.To learn more about the variety of die castable ZA alloys please visit: http://www.diecastingdesign.org/alloys/za.htm

New! Die Casting Coatings Report Available

Aluminum die castings are used in many modern applications. Although the raw surface of an aluminum die casting provides substantial protection, sometimes enhanced surface performance is required with the use of surface finishes.The new NADCA test report “Performance Evaluation of Surface Finishes on Aluminum Die Castings ” provides an evaluation of various surface finishes for aluminum die castings.

For more information and to order please visit: http://www.diecastingdesign.org/publications/309/

Casting Design Seminars at CastExpo’10

The Casting Designer and Buyer Tracks at CastExpo’10 will provide education on topics ranging from the basics of metal casting to casting design conversion and sourcing tips by a lineup of expert speakers.The seminars will be held in the Cast in North America Pavilion where metalcasters (including die casters) will showcase their casting capabilities.This area will allow buyers and designers to network with suppliers and provide an opportunity to discuss design challenges face-to-face with experts.In addition the winning castings from the 2010 International Die Casting Competition will be on display show casing the capabilities of the die casting process. For more information visit: www.diecastingdesign.org/castexpo/

Parting Lines

No, not the words you say when leaving work for the day… the lines that established on the surface of any cast part that define where the die will open releasing that part from the die.For simple parts the parting line may be automatically defined by the proper addition of draft to a part.For more complex parts the parting line may need to be consciously designed for product function and die casting manufactur ability. To learn more about the details of parting lines and how to get them to automatically appear in you CAD software visit: www.diecastingdesign.org/design/basic/parting_line/

partingline

Zinc Die Casting Alloys

Did you know that zinc alloys allow for the longest die life out of all the common die casting alloys.In addition the room temperature impact strength of zinc alloys is the highest of all die cast alloys. To learn more about zinc die casting alloys visit: www.diecastingdesign.org/alloys/zinc.htm

Die Casting Process Cuts Weight, Parts Count for Larger Auto Parts

When light weighting large parts and assemblies other manufacturing processes may come to mind besides die casting; however, die casting is now being used to advantage in production of larger thin walled parts.Automobiles from Nissans to Ferraris are now using light weight thin walled die castings for door assemblies and other large components, read more at the following links:

Article 1

Article 2

Alcon Labs Benefits From NADCA Design Seminar

The latest company to benefit from a NADCA Design seminar is Alcon Laboratories.A convenient option for any company, the NADCA Design seminar comes to you. Rather than sending a large number of your employees to a remote location, seminars are held on-site enabling them to be not only cost effective, but well-attended.

To learn more about having a NADCA Design Seminar at your company visit: www.diecastingdesign.org/seminars/

Draft Advantages

Draft is highly recommended for all die cast product designs.The proper amount of draft will allow production of a die casting that will be easier to remove from the die casting dieresulting in a higher quality final product.To learn more about the details and benefits of draft visit: www.diecastingdesign.org/design/basic/draft/ and www.diecastingdesign.org/design/basic/draft/advanced/.

Update: Chinese Knock-offs

In a recent blog post, Chinese Knock-offs Move Beyond Gucci Bags, I described how some high-end Italian machinery makers are seeing copies of their equipment pop up in China. They’re fighting back through technical innovation, lower-cost manufacturing, service, and quality.

But it made me wonder what sort of legal recourse they have, if any?

I asked Thomas Babel, an attorney specializing in litigation and intellectual property with the law firm Ward and Smith P.A. He says that it is difficult to prove that an innovation was stolen by a Chinese company.

To view the rest of this article, click here.

Aluminum 380, 383, 384 What’s The Difference?

This is an often asked question.380 is by far the most widely cast of the aluminum diecasting alloys, offering the best combination of material properties and ease of production. It may be specified for most product applications. Alloy 383 and alloy 384 are alternatives to A380 for intricate components requiring improved die filling characteristics. Alloy 383 offers improved resistance to hot cracking (strength at elevated temperatures).

For more details on the full range of available die casting alloys see Section 3: Alloy Data of the NADCA Product Specification Standards for Die Castings manual.All sections of this manual may be downloaded at no charge in PDF format after registering at the new NADCA Design website www.diecastingdesign.org Once registered check simply navigate to the “NADCA Standards” menu item.

Full-Scale Turbo-Prop Aircraft Engine Model Created with 3D Printing

The worlds first full scale turbo-prop engine model was recently produced with 3D printing.The full size physical model of the engine helped identify changes to improve the engine assembly.Some of the 3D parts are over 4.5 feet long.This new large format 3D printing capability is also suited for prototyping larger parts, that will eventually be die cast, for form, fit and function.For more information visit: http://www.businesswire.com/news/home/20091202006479/en

Design Track Registration Now Open

Do you want to attend our 2-day NADCA design seminar and CAstExpo’10?! Now you can do both! New for 2010 we are offering our NADCA Design seminar as part of CastExpo’10. The morning session of this seminar will provide an overview of designing products for die casting.Various considerations need to be taken into account and these will be reviewed. The afternoon session will provide details for die casting product design such as alloy properties and selection, dimensional capabilities, and tolerances.

This is your chance to attend CastExpo, Design Seminars and the Cast in North America Pavilion all at once! Designers are encouraged to sign up online at http://www.diecastingdesign.org/castexpo.

On-site Die Casting Design Seminar

Do you have a group at your company that would benefit from information on how die casting may be a good fit for new or existing products. Scheduling a NADCA Design seminar on-site at your company is one of the best ways increase knowledge about die casting related to your companies product line. The NADCA Design seminar covers all stages of a product lifecycle from development, design, specification, all the way to manufacturing and beyond. In the development stage of the seminar attendees will learn to identify when die casting is a good match for a specific product. In the design stage attendees will learn to optimize product performance through the features offered by die casting while simultaneously increasing product manufacturability. The specifications and properties of multiple die casting alloys will also be reviewed. In the manufacturing stage the NADCA Design Seminar will lead to greatly improved communication and understanding between the attendees and die casters who will make the final product. In addition Key die casting resources will be identified for future use by the seminar attendees. To learn more about having a NADCA Design Seminar at your company please visit: www.diecastingdesign.org/seminars

Web Based Die Casting Design Information

Instant die casting design information is available through the NADCA Design Website. Video modules are available on Product Development, Part Design, Alloys and the Die Casting Process. A link to Instant Support via e-mail and phone is provided. Connecting with a die caster is simplified through the Find a Die Caster Database. In additional valuable resources such as NADCA Standards, Commercial Practices Check Lists, Case Studies and a Die Casting Examples database are available. Connect now with all these valuable resources at: www.diecastingdesign.org

Chinese Knockoffs Move Beyond Gucci Bags

Notorious for copying items like handbags, videos, software, and bearings, Chinese manufacturers are getting even more audacious. They’re copying entire designs sold by some high-end Italian machinery makers and selling them in China at low prices, made possible by using lower cost components and avoiding import fees. In one case, one brazen company even attempted to register the original Italian manufacturer’s brand name here.

To view the rest of this article, click here.

Rapid cast prototypes enable parts to be assessed in a choice of alloys

When competition is fierce, the consequences of bringing a product to market late can be severe, with significant loss of market share and future profits. It is no surprise, therefore, to see the expanding use not just of rapid prototypes for investigating the form and fit of components but also components that are fully functional. Such rapid prototypes can provide high-strength, dimensionally accurate parts with all the features, operating capabilities, appearance and performance of the finished part. Because they can be delivered quickly and affordably, these rapid prototypes offer designers the means to compress development times and be more confident that the product will perform as intended for its required lifetime.

To view the rest of this article, click here.

Naked Die Casting Design

The new Kawasaki Z1000 2010 motorcycle features a “Super Naked” design that shows off mechanical parts rather than hiding them with a fairing. Kawasaki Engineers used multiple die castings to provide components that look aggressive and high tech while providing high performance functionality. Each die cast piece is functional and a work of art at the same time. Smooth, stylized, single piece die castings replaced multiple parts and welded assemblies in critical frame components. In addition components that were previously die cast easily accepted new as-cast visual styling such as the engine, brake calipers, and many other components. See the dramatic effect of the “Super Naked” design concept made possible by die cast parts in the Z1000 HD Video