Monthly Archives

February 2018

A Comparison of the Hot-Chamber and Cold-Chamber Processes

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Examining the Differences Between Hot-Chamber and Cold-Chamber Die Casting

What is Die Casting?

In the most basic terms, die casting is the process that involves the use of high pressure to force molten metal into a mold cavity to produce metal parts; these mold cavities are made of two hardened tool steel dies that are machined to conform to the specifications of the respective part or product.  For optimum results, most die castings are manufactured from non-ferrous metals i.e., metals that do not contain iron to any appreciable amount.

There are essentially two types of die casting processes – hot-chamber and cold-chamber:

What is Hot-Chamber Die Casting?

Hot-Chamber Die Casting Process – a pool of molten metal is forced into the mold cavity via pressure applied by a pneumatic-powered or hydraulic-powered piston.  The advantages of hot-chamber die casting include fast cycle times (up to 15 cycles per minute on average) and the convenience of melting the metal directly in the chamber/machine; a drawback to this process is its limitation to metals with low melting points only.

What is Cold-Chamber Die Casting?

Cold-Chamber Die Casting Process – use of this method requires the metal to be melted in a separate furnace then transported in precise amounts to the cold-chamber machine; this molten metal is then injected or shot into the mold by hydraulic or mechanical pistons.  Use of the cold-chamber die casting process is ideal metals with high melting temperatures; its primary disadvantage is longer cycle times, due to the additional step of transferring the molten metal from a separate furnace to the machine.

As intimated above, the metal point or metal temperature of the respective metal dictates the type of die casting process that must be applied; a synopsis of the common metals most often used in each method would include:

  • Hot-Chamber Die Casting
    • Low melting-point metals/alloys – zinc, lead, magnesium 
  • Cold-Chamber Die Casting
    • High melting-point metals/alloys – brass, copper, aluminum

In general, die casting is one of the most versatile metalworking processes; consequently, the use of die casting is common across a wide range of industries for the manufacturing of parts, components, and finished products in a variety of shapes and sizes.

Some examples of its application would include:

  • Golf equipment
  • Camera housings
  • Electronic housings
  • Locks and deadbolts
  • Pumps and compressors
  • Hospital bed control panels
  • Dental workstation baseplates

It is important to note that few metalworking/manufacturing methods can be applied for all products or with all types of materials, and this relates to die casting as well; some of the limitations of the hot-chamber and cold-chamber die casting processes are the lack of cost-effectiveness for low-volume production runs and its diminished efficiency when the weight of a part or product exceeds 75 pounds.

Precision Molds for Optimal Results in Hot-Chamber and Cold-Chamber Die Casting

Many of the production efficiencies/benefits associated with either method of die casting are directly dependent on the accuracy and quality of the molds used in the specific processes.  And while manufacturers might have the financial assets to invest in die casting equipment that can be used on a repeat basis, this may not be applicable to the one-time development of the actual mold or molds.

In order to achieve optimal benefits from their use of die casting, manufacturers might want to engage the mold-making expertise of the team at Noble Precision; these capabilities are supported by Noble Precision’s investment in state-of-the-art technology, specifically the latest in 5-axis simultaneous CNC machines and CAD/CAM software.

For further insight on the die casting services offered by Noble Precision, including precision mold making, see our die casting process page.

Call the precision mold making specialists from Noble Precision at 647-499-7569 today or contact us to request a complimentary consultation on our cutting-edge technologies and services and how we can support your hot-chamber and cold-chamber die casting needs.

Rapid Prototyping and Its Importance in Precision Manufacturing

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Rapid Prototyping and Its Advantages in Product Development and Manufacturing

By definition, rapid prototyping is the production of a scale model (prototype) of a physical part or product using multi-dimensional computer-aided design (CAD) software. The actual construction of that part or product is done via 3D-printing or additive layer manufacturing technology. And, in fact, the terms three-dimensional printing or additive manufacturing are often used interchangeably to describe the process of rapid prototyping.

Very often, when product designers want to demonstrate how new products will look, feel, and perform, they do so through digital models; while this is the more inexpensive method, it may not be conducive to gaining approval for the design from management and/or clients. Because these groups often want to see new products in physical rather than virtual form.

But building a physical model can be time-consuming, not to mention expensive. Especially if it is found after testing that the prototype needs to be altered before going to production.  And this is where rapid prototyping can offer a number of significant advantages, including:

  • Faster and more cost-effective than constructing a full-scale model
  • Eliminates the cost and time need to develop special molds and tools
  • Minimizes waste; uses only the material needed to build the prototype
  • Can make parts of miniscule size and/or that have complex geometries
  • Provides a realistic three-dimensional design vs a computer screen image
  • Permits the identification of any design flaws prior to any mass production
  • Design changes can be done without the need to modify the entire process
  • Easier testing – properties of the material closely resemble the final product
  • Changes can be made immediately, eliminating the need to wait for feedback

There are several processes that can be used for rapid prototyping; the most common are:

  • Stereolithography (SLA)
  • Selective Laser Sintering (SLS)
  • Fused Deposition Modelling (FDM)
  • Selective Laser Melting (SLM)
  • Laminated Object Manufacturing (LOM)
  • Multi Jet Modelling (MJM)
  • Digital Light Processing (DLP)

Determining which of the above types of procedures to use will be based on such factors as:

  • Production volume
  • Speed of production
  • Financial considerations
  • Geometry of the part/product
  • Intended use of the part/product

However, in order to appropriately align these production-related and cost-related factors to the right process among the various types of rapid prototyping, manufacturers and/or their designers may find it beneficial to consult with the experts from Noble Precision.  The team at Noble Precision has extensive experience in rapid prototyping, from very intricate parts to larger-scale models, and thus can ensure that their outputs from this methodology will meet the specifications, expectations, and business needs of their clients. 

Rapid Prototyping Service to Support Your Product and Parts Development Needs

Prototype development, while an important aspect to determining the ultimate viability of a part or product, may not be a practical option for manufacturers from a cost and operational perspective.  Fortunately, Noble Precision has made a significant investment in state-of-the-art technology, including the latest in CAD/CAM software, to alleviate any such concerns for their clients and allow them to partner with Noble Precision’s team of experts to adequately address these unique, single-unit production needs.

For additional information on the prototyping services provided by Noble Precision, including rapid prototyping solutions for many additive manufacturing applications.

Rapid prototyping is an excellent alternative to the traditional approach of creating full-scale prototypes; it allows the designers and the end-users to validate the dimensions, assembly, and functionality of new part or product without the need for special tools or experienced technical support, with the additional advantages of cost-efficiency and time-efficiency.

Call the experienced specialists at Noble Precision today at 647-499-7569 or contact us to request a complimentary consultation on the advantages offered by our state-of-the-art technology and rapid prototyping service relative to your product/parts development needs.