Die Casting Design for Manufacturability (DFM)

Typical applications

• New die cast part designs headed to tooling
• Existing designs being evaluated for cost reduction
• Parts moving from another die caster where design intent needs re-validation

Process overview

1. 1

   Wall thickness review

   Checked for uniformity to reduce porosity and shrinkage risk.

2. 2

   Draft and parting line review

   Draft and parting line location are proposed for reliable ejection and cosmetic result.

3. 3

   Machining allowance planning

   Features needing tighter-than-as-cast tolerance are flagged for secondary machining allowance.

Part design considerations

• Uniform wall thickness reduces porosity and warp
• Ribs and bosses should transition gradually to avoid stress concentration
• Features requiring tight tolerance should carry machining stock rather than relying on as-cast tolerance

DFM guidance

• Bring designs to us before tooling is quoted — casting-specific DFM issues (porosity risk, ejection, trim access) are easiest to fix on the model, not the die
• Tell us which features are functionally critical so machining allowance is planned in the right places

Quality controls

• DFM findings documented and shared before tool build begins
• First-article inspection validates the casting against the reviewed design

Secondary operations available

Frequently asked questions