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IMPORTANT NOTICE: A&B Die Casting is now a division of Benda Tool & Model Works, Inc.

IMPORTANT NOTICE: A&B Die Casting is now a division of Benda Tool & Model Works, Inc.

by | | Company Announcements

After over 70 years of serving our valued customers as separate companies, we are excited to announce that Benda Tool & Model Works, Inc. and A&B Die Casting Company, Inc. are merging into one company. Benda Tool will be acquiring A & B Die Casting as of January 1st, 2023. A&B Die Casting will continue to serve our customers as it always has as the production die casting division of Benda Tool & Model Works, Inc.

Questions or concerns?
Please contact us directly.

Die creation for die casting – what you need to know

Die creation for die casting – what you need to know

by | | Die Casting

A high quality die cast component begins with a quality die; and a quality die begins with a good tool design. Die design and creation will affect the overall quality, uniformity, shape, and configuration of your final cast parts. The die is a custom-engineered piece of equipment, typically made from heat-treated steel, which is composed of two halves. One part, or the cover die, is stationary. The second part, or ejector die, moves to meet the cover die. When the two halves meet, molten metal is injected into the tool where it solidifies and is then ejected as a final part.

It is always a good idea to partner with your die casting company early in your project in order to get the best quality casts possible. The die casting engineers can assess your project’s concept or existing part, from design to end product, and work with you to optimize the design for casting. To begin any die cast project, you need to have a die created for your specific part. Your die concept needs to address critical information such as:
• Critical tolerances
• Volume (both annual and lifetime)
• Functional requirements
• Cosmetic requirements
• Finishes
• Secondary operations
• Mating parts or assemblies
• Wall thickness
• Alloys used
• Project timing
• And more

There are also a few different types of dies used for die casting. Those include (but are not limited to) prototyping dies, production dies, and unit dies.

Prototyping dies
Prototyping dies are utilized because the full featured production die is a significant investment and thus you really only want to create one. So a prototype of the proposed production die is created to test fit and functionality to ensure accuracy. Prototype dies can be created from 3D printed parts, machined hog-outs, and more.

Production dies
Production dies are the most common dies produced. They can be single cavity dies with no slides or multi-cavity dies with any number of slides. These dies are typically made from high-quality steel and are retained within a holder block. These dies are built to critical dimensions to enable coring of the maximum amount of stock from the casting.

Unit dies
Unit dies are special types of production dies that are used for lower volume or smaller parts. They typically have a standardized main die frame with replaceable cavity units designed to be removed from the main die without having to remove the standard frame from the die casting machine. This feature allows for quicker setup time and more efficient low volume production runs.

What needs to be taken into consideration prior to die creation?
Aluminum offers so many attractive characteristics however there are still quite a few considerations that need to be taken into account before you build a die to cast your parts. Factors such as:
• Part design
• Mold configuration
• Tools used to create the die
• Part quality expectations
• Heat treatment techniques
• Die coatings
• And more

Die material
The grade of material used to create your die should be as high quality as possible. The die itself is repeatedly exposed to extremely high temperatures and pressures during the die casting process. Of course the die material selected is also contingent on the alloy that will be cast in the die, the critical characteristics of the part to be cast, and the long-term production requirements for the die. The choice of die material will affect both the lifespan of the die and the quality of parts cast.

Die design and creation affects the overall quality, uniformity, shape, and configuration of your final cast part. An improperly created die will result in inferior cast products, as well as tool or material corrosion. A die that fails will grind production to a halt and force you to spend more time and money re-building your die. Working closely with an experienced die caster will help you not only achieve the best possible product but also save you both time and money in the long run.

Ready to get started?
Start by downloading NADCA’s official tooling for die casting information and checklist HERE.

Then give us a call!
With over 75 years of die casting expertise, our team of interdisciplinary engineers will evaluate your requirements to help you decide which would be the best option to achieve the desired result for your part. Our in-depth knowledge and experience allows us to control the entire pre- and post-operative processing, as well as provide turn key part solutions with a variety of options, to meet your individual needs. Contact A&B Die Casting today to get started on your next project!

Pure Aluminum –VS– Recycled Aluminum

Pure Aluminum –VS– Recycled Aluminum

by | | Alloys, Die Casting

As we talked about in our last article, the die casting process is environmentally friendly in three major ways – it uses less waste, offers high accuracy, and long part life. The most commonly die cast alloy, and one of the most abundant in the world, is aluminum. The physical and mechanical properties of aluminum make it an ideal choice for many industries since it is durable, corrosion resistant, low density, and has a high strength-to-weight ratio.

If die casting is so environmentally friendly, does that mean that all alloys that are die cast are also environmentally friendly? Well, yes and no. Let’s look a bit closer at aluminum. Recycled aluminum alloys are very environmentally friendly but pure aluminum is not. Why?

Pure Aluminum
Pure aluminum actually used to cost more than gold. Not because it is a rare metal but because extracting it was (and still is) incredibly costly to do. Pure aluminum is extracted from clay ore called bauxite. The process basically involves carefully smashing the clay into a fine powder and separating the aluminum ions from the powder utilizing electrolysis. Extracting pure aluminum is energy intensive and detrimental to the environment due to mining destruction plus pollutants and large amounts of CO2 that are released during the extraction process. Though utilized in a few industries due to strict quality regulations, like the aerospace industry, Aluminum is very rarely used in its pure form because it also tends to crack and shrink.

Recycled Aluminum
Thankfully aluminum is 100% recyclable and approximately 75% of all aluminum ever extracted is still in use today. Recycled aluminum also only uses about 5% of the energy that is required to process pure aluminum. Aluminum can be recycled again and again without deterioration to its mechanical or physical properties – which means it will give the same level of performance as pure aluminum while being environmentally friendly and more cost-effective.

Most aluminum used today is mixed with other materials including copper, magnesium, and silicon. These other alloys help increase aluminum’s fluidity, elasticity, corrosion resistance, tensile strength, and hardness to provide it with even better mechanical properties. Recycled aluminum alloy die cast parts tend to maintain their strength at high temperatures, possess good thermal and electrical conductivity, are lightweight, and can be cast with intricate geometries and thin walls while maintaining their strength.

The benefits of using recycled aluminum to our environment include reduced energy consumption, reduced mining pollution, reduced shipping pollution, and reduced carbon dioxide emissions… all without sacrificing quality or strength. The ease of use in die casting combined with its environmentally friendly properties, lighter weight, and durability make aluminum a top choice for designers from nearly every industry.

Ready to get started?
A&B Die casting is committed to environmental safety, sustainability, and recyclability. We utilize only 100% recycled materials and offer an exciting array of recycled aluminum and zinc options along with providing high quality secondary surface finishes and treatments (such as paint, plating, and powder coating for functionality and decorative appeal).

With over 75 years of die casting expertise, our team of experienced engineers will evaluate your requirements to help you decide which would be the best option to achieve the desired result for your part. Our in-depth knowledge and experience allows us to control the entire pre- and post-operative processing, as well as provide turn key part solutions with a variety of options, to meet your individual needs. Contact A&B Die Casting today to get started on your next project!

Is die casting environmentally friendly?

Is die casting environmentally friendly?

by | | Die Casting

All industries today are concerned with waste disposal and the environmental impact of their manufacturing processes. Practically every nation has passed multiple laws designed to limit waste and protect the environment. When designing new parts it is important to not only design it for optimum functionality and easy fabrication but also its ultimate destiny at the end of its useable life. Basically, can the materials used to create the product be repurposed or recycled when the product is no longer useful?

A typical finished consumer product has more than one material used in its creation. For example, let’s look at an automobile. Approximately 75%-85% of the salvaged metal parts are removed and recycled at the end of the automobile’s useable life. However, a much lower percentage of plastics can be recycled and reused than most people know. Only about 9% of all plastics used (across every industry) can be recycled; the other 91% are dumped in landfills. This gives metal formed products a big environmental advantage over plastic products.

Die casting already boasts so many benefits – it is economical, efficient, repeatable, and reliable. Die castings also providing superior Electromagnetic Frequency (EMF) and Radio Frequency Interference (RFI) shielding properties over plastics, which help to meet ever increasing FCC requirements for many medical, telecom, and industrial applications. Did you know that die casting is also one of the most recyclable metal forming processes? Just about all metals and metal alloys are recyclable and since the die casting process does not include hazardous chemicals it poses no problems in handling or reprocessing the materials. Currently, over 95% of all aluminum die castings in North America are made from post-consumer recycled aluminum. Utilizing the recycled materials also saves energy on primary aluminum production which helps conserve nonrenewable energy sources.

Die casting is environmentally friendly in three major ways – it uses less waste, offers high accuracy, and long part life.

1.) Less waste
Reducing, recycling, reusing. Overall die casting produces less waste and consumes less energy than other metal forming processes. Die casting typically utilizes long-lasting reusable dies (or molds) and materials such as aluminum, zinc, and magnesium alloys which are easy to recycle. These factors help lower the environmental impact of creating the metal parts.

2.) High accuracy
High accuracy also has a positive impact on the environment. The die casting process creates parts that are exact to narrow tolerances, and does so repeatedly. Meaning you can cast thousands of identical items at specification without wasteful adjustments, unnecessary energy expenditure, or material scrap. You can also cast threads or other features directly into the part which eliminates some secondary operations and further energy expenditures per part.

3.) Long life
Die cast parts also do not degrade over time due to temperature fluctuations or UV exposure, which are common problems with other materials, such as plastics. They also provide excellent mechanical properties – strength, stiffness, durability, etc. Die cast metal parts eliminate, or reduce, the need to find new sources of materials which lowers potential chemical pollution from extraction and purification, damage to the ecosystem or water supplies from mining materials, overall energy consumption related to the work and transportation, and other negative environmental impacts.

Ready to get started?
A&B Die casting is committed to environmental safety. We utilize only 100% recycled materials and offer an exciting array of recyclable aluminum and zinc options along with providing high quality secondary surface finishes and treatments (such as paint, plating, and powder coating for functionality and decorative appeal).

With over 75 years of die casting expertise, our team of experienced engineers will evaluate your requirements to help you decide which would be the best option to achieve the desired result for your part. Our in-depth knowledge and experience allows us to control the entire pre- and post-operative processing, as well as provide turn key part solutions with a variety of options, to meet your individual needs. Contact A&B Die Casting today to get started on your next project!

Die creation thoughts… was yours designed with manufacturability in mind?

Die creation thoughts… was yours designed with manufacturability in mind?

by | | Die Casting, Engineering

A high quality die cast component begins with a quality die. The die itself determines the tolerances held, repeatability, strength, complexity, and how many parts can be created utilizing that single die. A well-designed die should incorporate as many features as possible to minimize post machining operations; thus saving money for the final unit part cost and faster throughput.

Designing your die for optimal manufacturability (or DFM) is what will truly makes it a high-quality tool. Keeping manufacturability in mind not only delivers a successful die but also one that will last and create more consistent, higher-performance parts.

It is always a good idea to partner with your die casting company early in your project in order to get the best quality casts possible. The die casting engineers can assess your project’s concept or existing part, from design to end product, and work with you to optimize the design for casting. They will go over specifics such as:
• Critical tolerances
• Wall thickness
• Functional requirements
• Cosmetic requirements
• Finishes
• Secondary operations
• Mating parts or assemblies
• Volume
• Project completion expectations
• And more

Though dies can be expensive to create, and it can be appealing to try to cut costs in this area, it is never a good idea to go with the lowest bidder when it comes to die creation. Die design and creation affects the overall quality, uniformity, shape, and configuration of your final cast part. An improperly created die will result in inferior cast products, as well as tool or material corrosion. A die that fails will grind production to a halt and force you to spend more time and money re-building your die. Working closely with an experienced die caster will help you not only achieve the best possible product but also save you both time and money in the long run.

A few other things to keep in mind to ensure a long-lasting and quality die that produces consistent high quality parts:
• Make sure that your die is created with high-quality materials by an experienced shop
• Allow for some wiggle room in tolerances for non-critical design elements
• Plan for some flexibility in the draft angles of non-critical design elements (this will help ensure easy part extraction which will extend the life of the die)
• Make sure to partner with your die caster early in the process (that way their engineers can help make adjustments in the design phase which will save you some money avoiding re-designs)

Ready to get started?
A&B Die Casting utilizes 3D models and our FDM (Fused Deposition Modeling Machine) to check die layouts for part design fit and moldability. This helps us quickly address potential design for manufacturability (DFM) issues so that we can optimize the design for the die casting process. Utilizing our FDM in this manner also allows us to revise the design prior to the creation of the production die which saves you both time and money.

With over 75 years of die casting expertise, our team of experienced engineers will evaluate your requirements to help you decide which would be the best option to achieve the desired result for your part. Our in-depth knowledge and experience allows us to control the entire pre- and post-operative processing, as well as provide turn key part solutions with a variety of options, to meet our customer’s individual needs. Contact A&B Die Casting today to get started on your next project!