In the world of die casting, tool life can impact a project’s successful outcome. Deco Product’s engineering expertise and experience in zinc die-casting can make a substantial difference in tool life. With such considerations, initial tooling costs are not only lower, but the tool life and piece cost for the long term is optimized.
In this blog post, we will explore why longer tool life matters. Along with why zinc alloys and great tooling support and engineering are the key to achieving these impactful results.
The Significance of Longer Tool Life
In die casting, the tool life will have a direct effect on the bottom line of our customers. When a mold is not properly designed or maintained, it is likely that an increase in part scrap will result causing efficiencies and higher cost. Additionally delays or disruptions in production can cause further stress for customers.
Replacing tools frequently can be a substantial financial burden— it can be a significant cost, but also source of extra work and stress for many critical customer resources for approving tooling plans and part approvals.
As such, Deco pays great attention for optimization in tool design. Deco’s engineering team will collaborate with customers during the design phase of a project to ensure longer tool life for both economic and quality reasons.
Zinc vs. Aluminum Tooling
In die casting, the choice between zinc and aluminum alloys can have a profound impact on tool life and overall performance as it is commonly understood that a zinc alloy mold will last 10 times longer than an aluminum mold.
Zinc molds are exceptionally durable. This results from zinc alloy’s lower abrasiveness and melting temperature compared to aluminum. As such, zinc is gentle on the tool steel it contacts, ensuring longer-lasting molds. In contrast, aluminum’s abrasive nature and higher melting point lead to quicker tool wear and deterioration.
But why does this matter? When a tool is excessively worn, it negatively affects part quality. Worn tools can result in defects like increased flash and other imperfections in the die cast parts.
These defects reduce product quality, increase production disruptions and require more frequent, costly tool repairs or replacements. By choosing zinc in your part design, you not only extend tool life but also ensure a higher part quality for many more years.
Cost Savings with Zinc Die Casting
Deco Products feels the financial advantages of zinc die casting are substantial. One key benefit is the reduction in both mold replacement, and Production Part Approval Process (PPAP) costs.
By choosing zinc for die casting, you are not only investing in a material known for its durability. But also, in a strategy that helps you save money throughout the production process.
Zinc molds last longer, reducing the need for repairs and replacements and minimizing disruptions and stress. This aligns with the goal of many customers for optimizing performance for the entire part life cycle.
Die Management for Longer Tool Life
At Deco Products, optimizing tool life is a priority and with decades of experience we have established the best methods for die management.
We have standard practices for ultrasonic cleaning, a two-stage process that breaks down any residue from the previous production run. This thorough cleaning ensures that our molds begin each new production run in top-notch condition.
Additionally, our process includes a rust inhibitor rinse, safeguarding the integrity of the tools and preventing corrosion.
Furthermore, our well-staffed tooling department operates around the clock, with continuous maintenance and supervision. This dedication ensures minimal production interruption, keeping your operations running smoothly.
Deco Products is unwavering in its commitment to delivering high-quality parts that consistently exceed our customers’ expectations. Our dedication to precision, innovation, and attention to detail ensures that every product leaving our facilities is of the utmost quality.
We understand the importance of maintaining quality throughout the entire production process, from tooling to final output. This commitment is not just a promise; it’s a core value that has been upheld since 1960, and it’s the foundation on which our reputation has been built. We take immense pride in our ability to consistently meet and exceed the expectations of our valued customers.
In conclusion, the advantages of using zinc alloys in die casting for longer tool life are undeniable. The extended tool life, reduced mold costs, and ongoing production with less disruption and stress make zinc alloys the wise choice for die casting.
Deco Products, with its decades of experience and commitment to quality, stands as a testament to the effectiveness of zinc alloys in optimizing production processes. By choosing zinc, you’re not just achieving cost savings; you’re securing the highest quality in your products, ensuring both your bottom line and customer satisfaction are established.