What is Thin Wall Die Casting?
Thin wall casting of aluminum alloys allows for casting lighter parts. The parts have a high strength-to-weight ratio and large quantities of custom aluminum parts can be produced economically. It is adaptive to almost all kinds of unique shapes and sizes.
These die casting process also provides excellent dimensional accuracy. It forms thin wall deep cavity castings for complex shapes with clear contours. This is particularly suitable for integrated designs after overall formations.
Thin Wall Casting Specifications
While casting different ferrous or non-ferrous alloys, different specifications have to be used for wall thickness. Non-ferrous alloys, like aluminum, require a 2.0mm to 4.0mm wall thickness for thin-walled die casting. Ultra-thin wall casting features a wall thickness of less than 2.00 mm.
More sophisticated precision machining equipment is required to achieve the tighter tolerances needed for the tooling of thin wall casting molds. Check out the aluminum die casting design guide if you need more information on thin wall design.
Thin Wall Casting Pros and Cons
Wall thickness plays an important role in die-casting manufacturing. Here we have highlighted the key advantages of providing thin walls in castings,
- Excellent strength-to-weight ratio
- Efficient and simplified production
- Reduction of assembly for casting
- Achievable net shape configuration
- Steadfast dimensional precision
- Cast large sizes and complex shapes
- Little to no machining is necessary
- Simple production of exterior threads
- Multiple surface finishing techniques
The drawbacks of using thin wall casting of aluminum parts are as follows,
- Mostly cost-efficient when dealing with large volumes only
- High initial cost due to prototyping and tooling requirements
- The casting process results in more porosity
- Tighter tolerances are required for fillets/radii and drafts
Applications of Thin Wall Aluminum Casting
Superior mechanical properties make these thin-walled cast parts a preference all across the globe. Some of the major industries utilizing the benefits are as follows,
Automotive – The automobile industry requires many complex parts of critical sections. Thin-wall cast parts cover the complexity and meet the mechanical requirements.
Aircraft – However, the aerospace industry doesn’t need unique yet complex parts. They use considerably lightweight specifications against high-strength performance.
Manufacturing – Production of certain engines, tools, and associated parts requires complex shapes that are easily achievable through thin wall casting.
Medical – Surgical and biomechanical devices extensively use die-cast having thin walls. They keep the tools light yet strong enough to handle rigors/mess in medics.
Military – The military industry keeps implementing new technology and weapons. Thin-walled casts have been helping design lightweight and durable weapons.
Commercial – Thin wall cast components have many commercial applications in various sectors. It has proven to be a cost-effective substitute for more expensive metals. But does not compromise the performance.
Sunrise Metal is a leading aluminum die castings manufacturer in China. We have engineers and professionals with over ten years of experience in the die-casting industry. Contact us to discuss your requirements for thin wall die casting aluminum today.