Every successful manufacturing run starts with exceptional part design. We partner with you early in the development phase to optimize your aluminum and zinc components for the high-pressure die casting process. Taking the time to refine your design upfront reduces tooling costs, minimizes material waste, and accelerates your overall production schedule at our Macedonia, Ohio facility.
Designing for the die casting process requires a deep understanding of how molten metal flows and solidifies. Our engineering team will review your blueprints and help you optimize several critical structural elements:
Wall Thickness
We'll help you identify the optimal thickness for your specific parts to prevent internal voids and reduce weight without sacrificing structural integrity.
Draft Angles
Our team calculates the ideal draft angles for your specific geometry to extend the life of the tooling and prevent cosmetic surface defects.
Fillets and Radii
Adding appropriate radii and fillets to your design smooths out the molten flow, strengthens the casting, and improves the final surface finish.
Ribs and Bosses
We work directly with your team to place ribs and mounting bosses strategically. This maximizes part rigidity while keeping material usage to an absolute minimum.
We don’t expect you to navigate these technical requirements alone. Our engineers leverage decades of experience alongside advanced MAGMA simulation software to test your designs virtually before our in-house Tool and Die Shop cuts any steel. We analyze thermal dynamics, optimize gating layouts, and predict potential manufacturing challenges early in the process. This proactive collaboration means your design is completely optimized for reliable, high-volume production.
