✅ Advantages of Die Casting
1. High Production Rate
- Very fast cycle times
- Excellent for mass production
- Lower cost per unit at high volumes
2. High Dimensional Accuracy
- Tight tolerances
- Good repeatability
- Less need for secondary machining
3. Excellent Surface Finish
- Smooth surface directly from the die
- Minimal finishing required
- Good for decorative or visible parts
4. Complex and Thin-Walled Parts
- Can produce intricate shapes
- Thin sections possible
- Good for lightweight components
5. Good Mechanical Strength
- Dense, strong castings
- Suitable for structural and load-bearing parts
6. Material Efficiency
- Low scrap rate
- Excess material can often be recycled
7. Ideal for Non-Ferrous Metals
Commonly used with:
- Aluminum
- Zinc
- Magnesium
❌ Disadvantages of Die Casting
1. High Initial Tooling Cost
- Expensive dies (molds)
- Not economical for small production runs
2. Limited to Non-Ferrous Metals
- Not suitable for steel or iron
- Mainly used for aluminum, zinc, magnesium alloys
3. Porosity Issues
- Air entrapment may occur
- Can reduce strength
- May affect welding or heat treatment
4. Size Limitations
- Not ideal for very large castings
5. Die Wear
- Dies can wear out over time
- Maintenance costs must be considered
📌 When Die Casting Is Best
- High production volume
- Complex parts
- Tight dimensional tolerance required
- Good surface finish needed
- Long-term production planning
