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Size
No limitation but best range within 2 in. cube to 36 in. cube.
Finish
Can hold 63 micro-inch, but normally 90 micro-inch.
Shape
Considerable design freedom for unusual and complex shapes.
Wall thickness
Thin wall: 0.030 in. - 0.060"
Average: 0.080 in. - 0.120 in.
Thick wall: 0.180 in. - 0.500 in.
General tolerances
0 in. - 2 in. +/- 0.010 in.
2 in. - 3 in. +/- 0.012 in.
3 in. - 6 in. +/- 0.015 in.
6 in. - 12 in. +/- 0.020 in.
12 in. - 18 in. +/- 0.030 in.
18 in. - 30 in. +/- 0.040 in.
Limitations
The process is limited to non-ferrous metals with pouring temperatures below 2,000 ºF - this includes aluminum, zinc casting alloys and some copper based alloys.
Holes
Not economical to cast small holes (1/4 in. or less) unless odd shape or inaccessible areas for machining.
Alloys
All aluminum and zinc casting alloys to the commercial and military specifications. See separate technical sheet.
Draft
Typically 1/2 to 2 degrees.
Zero draft is possible in specified areas.
Corner radii and fillets as required, typically 1/16 in.
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Mechanical properties
Tensile - Yield - Elongation - as per the appropriate commercial and military specifications. See separate technical sheet.
Tooling - pattern equipment
- Loose pattern - to expedite for up to 20 pieces.
- Epoxy resin - usually up to 500 pieces.
- Metal - aluminum or brass - used to obtain best tolerance and quality.
- Rubber - for quantities up to 1,000 pieces. Tooling can be duplicated easily from master tooling to expedite delivery or for higher volumes.
Cost
Rule of thumb for complex shapes within a 15 in. cube:
Tooling: 10% of die cast tools.
Piece price: 10 times die casting price.
Delivery
1 - 2 weeks for simple parts.
6 - 8 weeks for complex parts.
Typical applications
- Castings for telecommunications, business machines, medical equipment, computers, automotive, aerospace, electronics and robotics.
- Molds for plastics industry - rotational molds, vacuum form, expanded polystyrene molds, kirksite injection molds.
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