How to Calculate Die Casting Cost in 2023?

Susan
May 23, 2023
10:23 am

Calculating cost of die casting involves several steps but the main factor of high pressure aluminum parts price in the order quantity, materials, and customization. Usually, die casting parts manufacturing cost ranges from $10 to onward. But we would recommend getting an online quote for your order.

This article will discuss how to calculate die casting cost and the costs associated with each step in the production process.

Cost and quality management, corporate strategy, and the idea of project management. A businessperson using a digital tablet to conduct productive business while monitoring quality control growth Cost and quality management, corporate strategy, and the idea of project management. A businessperson using a digital tablet to conduct productive business while monitoring quality control growth manufacturing cost stock pictures, royalty-free photos & images

Following are the three primary factors that affect the cost of the die-casting manufacturing process, and we’ll provide some guidance on how to reduce and calculate these costs:

Material cost
Production cost, and
Mold cost

What Should You Know About Material Cost?

The cost of the material is determined by the needed material weight and the material’s unit price. Although the maximum wall thickness of the parts can also be effective, the weight of the material is certainly influenced by the part volume and material density.

The required material weight involves material that fills the die channel. It takes more material to fill portions with thinner walls because a larger channel system is needed so that the entire part fills fast and evenly.

However, due to the thinner walls, such additional materials are often less than the materials saved by partial volume reduction. Therefore, using thinner walls will result in cheaper material costs even with wider channels.

What Should You Know About Production Costs?

The cost of production is mostly determined by the hourly rate and cycle time. It’s important to understand how the part’s design influences the machine choice because the hourly rate is inversely proportional to the capacity of the die-casting machine. Die-casting machines are often identified by the amount of clamping force they can provide in tones.

As a result, larger components need a stronger clamping force, which calls for a more expensive machine. Additionally, larger tonnage machines might be necessary for particular materials requiring high injection pressures. The part’s size must also adhere to other machine requirements.

The type of machine (hot chamber vs. cold chamber) and its size also have an impact on price. It would be more expensive to use a cold chamber machine when using materials with high melting points, like aluminum.

The cycle time is divided into three parts: injection, cooling, and resetting. These periods can be cut down, which will lower production costs. Reducing the part’s wall thickness will shorten the injection time.

A cold chamber machine process requires molten metal to be poured into the machine, which greatly increases production time, so using a hot chamber machine can save a lot of time. The cooling time is also influenced by the material’s thermodynamic characteristics.

How Much Does Mold Cost? What Should You Know?

One of the most successful and practical strategies to reduce die-casting costs in the die-casting industry is optimizing mold design and reusing existing molds.

Reduced Costs through Mold Flow Analysis

Historically, engineers’ expertise was used in both mold design and production. Repeated tests were necessary as part of the mold creation and design process, and the mold had to be continuously updated in response to the test results. The cost and length of the product development cycle rose with each trial.

Engineers can see the true flow and solidification of the liquid metal inside the mold during die casting using simulation analysis, allowing them to optimize mold design and procedure while saving costs.

Reduce Mold Costs by Using Core

Many products are similar in design and can be used on various models with minor adjustments. We can think about assembling several components into a core for this kind of product and creating two molds to produce a range of goods.

For example, the natural gas joints on both ends of our standard natural gas meters come in many different varieties, one of which is a product joint.

We may divide up the joints into many cores, which lowers the expense of having multiple sets of molds for various goods. It is possible to quickly generate another product without having to create a new mold if the core has a quick-change structure.

Reduce Mold Costs by Reusing Old Molds

The cost of a set of molds will go up when many molds near the end of their service life and a replica mold procedure is required. We can use an old mold with a solid mold frame. The cost of a set of mold frames can be reduced by only having to redo one set of cores and using the new mold core with the old mold frame.