Design Guide: Die Casting
Design stronger, highly manufacturable metal die-cast parts while minimizing tooling costs and avoiding common casting defects.
Download the Guide
A solid CAD model is only the beginning. Creating a truly successful die-cast part comes down to understanding how molten metal actually behaves once the tool closes. We wrote this Design for Manufacturability (DFM) guide to bridge the gap between engineering theory and the physical realities of the shop floor. Inside, we unpack the practical rules of casting geometry, from optimizing wall thicknesses and safely spacing ribs, to strategically placing gussets and eliminating subtle defects like sink marks. Download the full guide today to equip yourself with the real-world insights needed to reduce tooling costs, avoid production headaches, and engineer highly manufacturable metal die-cast components from the very first shot.
Table of Contents
Introduction to Die Casting
- Overview
- Types of Die Cast Tooling
- Understanding Die Casting Systems
Die Casting Materials
- Overview of Alloys
- Common Materials
Die Casting Finishes
- Overview of Finishes
- NADCA Surface Finishes
Die Casting Design Guidelines
- Draft Angles
- Wall Thicknesses
- Bosses, Ribs, and Gussets
- Radii and Fillets
- Integral Hinges and Pivot Points
- Text and Symbols
- Gate Placement and Vestiges
- Parting Lines and Flash Management
- Die Casting Tolerances
Common Defects and How to Prevent Them
- Porosity and Gas Entrapment
- Cold Shuts and Misruns
- Flash and Soldering
- Sink Marks
Additional Resources
About Xometry
Xometry offers instant pricing for manufacturing, including precision CNC Machining, 3D Printing, injection molding, and Urethane Casting services. Xometry also provides live engineering support from our team of experts. Upload a 3D CAD file to get a quote.