Casting process

Various processes are applicable according to the type and quantity of parts to be manufactured

Two major ways arise :

Non-permanents mouldsThe mould is destroyed to pull out the part
Prototype and pilot series of parts manufacturing
Limited manufacturing rate
The time to make the mould is higher than the time to cast
Permanent mouldsThe mould often in metal is reused to make several series of partsMass production rate
Dimensional stability of produced parts
Possible part shapes are more limited because the part needs to be extracted from the mould

Die-cast moulding  (process used at DEJOIE) :

  • Permanent mould, mainly made of steel, alloy cast with a ladle
  • Series of several thousand parts
  • The parts show a good surface quality
  • The parts show good mechanical properties

Die-casting :

  • Similar to die casting moulding except that the alloy is injected into the mould through a piston or a cylinder
  • This technology is used for mass production
  • The parts show a good surface quality
  • Possibility to manufacture thin-walled parts

Sand casting :

  • Moulding of a model or pattern plate in frames full with sand and alloy casting in the cavity left by the model
  • Capacity to manufacture large and complex parts with holes thanks to the use of cores in the mould
  • Applicable for prototyping, from a few to several hundreds of units
  • Medium surface quality and medium dimensional precision

Practical advice for designing parts througbh die casting moulding :

Avoid isolated masses
Avoid variations in part thickness, favour a molten alloy path
Avoid useless masses