RapidoParts Engineering Support
From concept validation to first-off-tool, our engineering team works alongside yours, optimising designs for manufacturability, reducing cost, and eliminating defects before production begins.
CAD
Design Support
DFM
Optimisation
MAGMA
Casting Simulation
±0.05mm
YAchievable Tolerances
Die casting is one of the most capable and efficient metal manufacturing processes available but unlocking its full potential demands engineering precision at every stage. A part that is sound on paper can harbour expensive problems in the tool: porosity, shrinkage, ejection failure, or dimensional drift.
Engineering Support at Every Die Casting Stage
- Our engineers work directly in CAD alongside your design team whether you’re starting from a concept sketch, a 2D drawing, or a partially-developed 3D model.
- We model, modify, and optimise geometry for die casting, ensuring your files are production-ready before tooling begins.
- From wall thickness corrections to complex parting line definition, we handle the detail so your team can focus on function.
- Design for Manufacturability is the single most cost-effective investment in any die casting project.
- Our DFM reviews systematically examine every aspect of your component draft angles, fillets and radii, wall uniformity, boss geometry, ejector pin placement, and parting line strategy.
- You receive a clear, annotated report with specific, actionable recommendations that reduce tooling risk and improve first-off quality.
- Bring us in early. Our product design consultations are structured conversations between your engineers and ours exploring how die casting can best serve your application, what design freedoms the process enables, and where the constraints lie.
- We challenge assumptions, propose alternatives, and help you make informed decisions on geometry, alloy, tolerance, and finish before a single line of tooling budget is committed.
- We use MAGMA’s industry-leading casting process simulation software to model mold filling, solidification, and thermal behaviour with high fidelity. Before your tool is built, we can predict porosity zones, shrinkage risk, cold shuts, and air entrapment.
- MAGMA simulation allows our engineers to virtually test and optimise gate locations, overflow placement, and process parameters, giving you confidence in the design before any steel is cut.
Design for Die Casting
- The most common and costly die casting problems are almost always rooted in design decisions made long before the tool is ordered.
- Understanding the basics of die casting design principles is the single most effective way to reduce cost, shorten lead times, and ensure consistent part quality
Wall Thickness & Uniformity
Inconsistent wall thickness is a primary driver of porosity and shrinkage in die castings. Thick sections cool more slowly, creating isolated pools of liquid metal that solidify under tension — resulting in internal voids.
Draft Angles / tool damage
Surfaces parallel to die opening need draft: 1–3° external, up to 5° internal. Insufficient draft causes sticking, tearing, tool damage, ejection failure.External walls: min 1° (2° textured)Internal cores: 2–5°
Porosity & Shrinkage Management
Porosity (gas-induced or shrinkage-driven) is die casting’s top quality challenge. Our simulation predicts high-risk zones pre-tool building, enabling gate/overflow/vent repositioning in design.
Tolerances & Precision Guidance
Features across the parting line, near moving cores, or in deep cavities carry inherently wider tolerance bands. Our engineers provide tolerance guidance that reflects real-world process capability.
Generous Fillets and Radii
Sharp internal corners stress risers—both casting. Generous fillets & radii improve metal flow, reduce stress concentration in solidified part, extend die life. Recommendation is a 1mm minimum internal radius.
Bosses, Ribs & Ejector Pin Placement
Bosses need adequate support to resist ejection forces without distortion. Ribs boost stiffness without extra mass, but avoid root shrinkage. Ejector pin placement requires collaboration between part and tool design
Alloy Selection Guide
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| ALLOY FAMILY | KEY PROPERTIES | TYPICAL APPLICATIONS | Engineer’s Review |
|---|---|---|---|
| ALUMINIUM | MOST COMMON Excellent strength-to-weight ratio, good corrosion resistance, wide range of alloys (A380, ADC12, A360) | Automotive structural components, housings, brackets, heat sinks, consumer electronics enclosures | Most versatile die casting metal. High-pressure processes achieve complex geometries with tight tolerances. |
| ZINC | High precision, low melting point, excellent surface finish, near-net-shape capability | Small intricate components, hardware, connectors, | Enables the finest achievable tolerances and thinnest wall sections. Long die life. |
| ALLOY FAMILY | KEY PROPERTIES | TYPICAL APPLICATIONS | Engineer’s Review |
|---|---|---|---|
| ALUMINIUM |
MOST COMMON Excellent strength-to-weight ratio, good corrosion resistance, wide range of alloys (A380, ADC12, A360) |
Automotive structural components, housings, brackets, heat sinks, consumer electronics enclosures |
Most versatile die casting metal. High-pressure processes achieve complex geometries with tight tolerances. |
| ZINC |
High precision, low melting point, excellent surface finish, near-net-shape capability |
Small intricate components, hardware, connectors, decorative parts requiring plating |
Enables the finest achievable tolerances and thinnest wall sections. Long die life. |
| MAGNESIUM |
Lowest density structural metal, excellent stiffness-to-weight, good EMI shielding |
Automotive interiors, handheld devices, aerospace brackets, camera bodies |
Requires controlled handling. Optimal where mass reduction is a critical engineering objective. |
| ZINC-ALUMINIUM (ZA) |
Higher strength than standard zinc, improved bearing properties |
Mechanical components, bushings, structural parts with load-bearing requirements |
Bridges the performance gap between zinc and aluminium alloys. |
Start Your Project With Rapidoparts
Your Valuable Custom Manufacturing Partner!
From Rapid Prototyping to Production，Quality Parts. Fast. Easy. Affordable.
- +1(502)422-1539
- info@partmfg.com
- 2110, Block A, Building 2, Sihai Yunchuang Building, Houting Community, Shajing Street, Bao'an District, Shenzhen
