Die Cast Housing: The Ultimate FAQ Guide

Choosing high quality die cast housing requires in-depth knowledge on the product.

That is exactly what this guide explores – so if you want to learn more about die cast housing, read this guide.

What Is Die Cast Housing?

A die casting housing is a product that you make using the different types of die casting processes.

Besides, the die cast housing is helpful in several applications like battery covers for automobiles, telecommunication housing, etc.

die cast housing

die cast housing

Some examples of die cast housing include:

  • Enclosures
  • Shells
  • Covers, etc.

Can You Make Cost-Effective Die Cast Housing?

Yes, the manufacturers can use different methods to increase the quality of the die cast housing.

They can also improve the design at lower production costs.

Here are some elements that determine the cost of the die cast housing:

  • Production

The die cast housing can require intense work and this depends on the complexity of the component.

It may also need you to melt the metal alloy for your application.

  • Secondary processes

These are processes that enhance the surface or aesthetics of the die cast housing.

Examples of secondary processes you can conduct include:

  1. Finishing
  2. Spraying
  3. Machining
  • Finishing

This entails operations like plating, engraving, artworks, or silk screening.

As you plan how to manufacture other die cast housing parts, ensure you consider the entire assembly process and not just the housing frame.

Die cast housing can also be affordable since you can use one segment to supplant other different components.

Other factors that may affect the price of the die cast housing include the following:

  • The complexity of the component
  • The die casting metal alloy
  • Specific component finishing
  • The specific part tolerance

Involving engineers early in the production phase can minimize the cost of the components.

What Are The Advantages Of Using A Die Cast Housing?

A die cast housing has several advantages for the intended application.

Some of these benefits include:

  • The die cast housing parts are stable dimensionally and long-lasting
  • It can achieve a high production rate
  • Using aluminum metal to make the casting will provide impressive corrosion resistance properties
  • It is highly solid that the elective injection moldings of plastics
  • The process will effectively manage complex configurations within nearer tolerances
  • It allows the inclusion of external strings on the components in the die cast housing
  • The process enables you to combine several operations within a single complex-shaped component
  • It produces surfaces that are smoother compared to other casting components made from i.e. permanent molds
  • The ability to produce several similar castings due to large-scale production
  • It allows you to make parts and products that are thin-walled
  • Other components like studs and bosses are imperative this will minimize some expenses
  • It allows you to plate aluminum die cast housing with surface preparation processes

What Are The Emerging Trends In Die Cast Housing?

There are modern machinery and technological advances that are offering minimal labor requirements, high precision, and consistency.

When you employ both automatic processes and experienced staff, you will quickly identify issues with the process.

This allows you to correct the undesired variables early in the production stage.

To enhance the surface finish and legitimacy of the molds and die cast housing, you can use special vacuum frameworks.

This ensures that the clients receive the best work possible.

New technology also employs robotic work cells and other process monitors that will enhance the flow process and lower waste production.

This will allow manufacturers to make high-quality die cast housings that surpass the client’s requirements.

Besides, you can involve strict quality-control methodologies to identify and erase all die cast housing deficiencies.

Which Industries Use A Die Cast Housing?

There are many areas where a die cast housing will find its application.

Some of these usages include the following areas:

  • Medical field
  • Marine application
  • Recreational vehicles
  • Firearms
  • Automotive industries
  • Telecommunication industries
  • Outdoor lighting fixtures
  • Industrial equipment
  • Traffic lights
  • Computer industries

Which Metal Is Common With Die Cast Housing?

There are several metal alloys you can use when manufacturing die cast housing.

However, aluminum metal offers a suitable outcome as they have several benefits.

One of their traits is that they are lightweight and can resist a majority of different operating temperatures.

Also, aluminum has suitable electrical conductivity and thermal conductivity traits, as well as corrosion resistance.

Furthermore, aluminum will provide impressive quantities of finishing features.

Examples of aluminum alloy you can use in the fabrication of die cast housing include:

  • A380 aluminum alloy

This alloy is readily available and affordable.

It also provides suitable utility and price combination elements.

  • ADC12 aluminum alloy

This alloy will offer suitable die filling.

However, it will sacrifice a little of the mechanical characteristics like tightness.

  • AlSi12 aluminum alloy

This alloy is suitable for usages that need high strength, wear-resistance, bearing characteristics, and fluidity.

  • AlSi9Cu aluminum alloy

This alloy offers high levels of ductility and is suitable where the performance will need it to have elongation characteristics.

What Properties Make Aluminum Alloy Suitable For Die Cast Housing?

Aluminum alloy is lightweight and you can use it to make die cast housing without compromising on its strength.

When you compare aluminum with other non-ferrous metals, it offers more options when it comes to surface finishes applicable.

Also, aluminum can withstand high working temperatures.

Besides, aluminum is corrosion-resistant, suitable strength-to-weight ratio, has suitable mechanical properties, is highly conductive, and stiff.

aluminum die cast housing


aluminum die cast housing

The process of aluminum die casting relies on quick production processes thus you can manufacture a large amount of die cast housing rapidly.

Furthermore, aluminum is a recyclable material meaning you will minimize waste production during the manufacturing process.

This makes it good for the environment.

Aluminum will also enable you effectively make complex 3-dimensional designs at lower cost margins.

What Should You Consider When Selecting Alloys For A Die Cast Housing?

The material you will select for your die cast housing depends on the environmental conditions.

Aluminum material is the most abundant metal in the world and this makes it widely used in several applications after steel.

Some aspects you should consider when selecting aluminum metal alloy fall under two categories, the physical and mechanical properties.

  • Physical properties
  1. Thermal conductivity

Aluminum alloy has three times more thermal conductivity than steel.

This property makes aluminum a vital element in both heating and cooling usages.

  1. Reflectivity

Aluminum alloy is a suitable reflector when it comes to energy and radiation rays.

  1. Density

The most lightweight metal element available is aluminum metal.

  1. Electrical conductivity

An aluminum alloy has a highly sufficient electrical conductivity level making it suitable for use as an electrical conductor.

  1. Corrosion resistance

A layer of aluminum oxide will form on the surface of the aluminum metal when you expose it to air in the environment or oxygen.

This layer is resistant to corrosion thus making the aluminum alloy durable for use in several environmental conditions.

  1. Strength

Aluminum is suitable for use in cold environments.

Besides, it will maintain its rigidity as the tensile strength increases with decreasing temperature levels.

  • Mechanical properties

These include:

  1. Elongation
  2. Yield strength
  3. Impact strength
  4. Tensile strength
  5. Hardness
  6. Shear strength
  7. Youngs modulus

Why Is Aluminum Vital In A Die Cast Housing?

Die cast housing made from aluminum are electrically conductive and you can also efficiently ground them electrically.

Besides, aluminum usage happens in large and small scopes such as enclosures.

Here are the properties that make aluminum a suitable metal in the construction of enclosures and boxes:

  • Durable

Aluminum alloy is long-lasting and items you make from it are stable.

  • Protection of internal materials

Aluminum alloys react at a slow rate with the environmental air.

  • Lightweight and suitable texture

Aluminum is a light material and has an appealing surface finish.

What Is The Purpose Of Prototypes In Die Cast Housing?

When designing a die cast housing, you are making sure that the final product is suitable for the select application.

An important part of die cast housing design process is making prototypes.

The prototypes will give life to the design and engineering needs.

Administering prototypes will enhance the production and quality of the products.

Examples of innovations that help you actualize the die cast housing include:

  • Extensive prototyping
  • Rapid prototyping
  • Prototyping forms
  • Prototyping components

Besides, they assist you in making the final die cast housing surpass the desires of the customer.

What Techniques Will You Use To Ensure Quality Products From Die Cast Housing?

The following methods will make sure that you maintain the quality of the die cast housing:

  • Analysis of components

This process is important when checking the aluminum parts after the melting phase.

  • Management and measurement of dimensions

This entails inspecting the item, mold shape, and center to ensure a steady die cast housing.

  • Dimensional check

This entails monitoring the size and evenness of the product, especially in large production phases.

  • Micro CT scanning

This process is important when you are measuring the internal issues of the die cast housing.

Also, it allows you to inspect the internal parts without damaging the product.

  • X-ray tests

This technique is vital when you are inspecting internal issues of the die cast housing.

Why Are Thermal Characteristics Important In Die Cast Housing?

Heating plates are usually in research center gears and homes that require continuous heating.

The heat plates need materials that contain thermal characteristics suitable to take on the function of heating plates.

Aluminum happens to be the most preferred material in a die cast housing.

Besides, the use of die cast housing as heating plates is affordable and convenient.

What Are The Features Of An Effective Die Cast Housing?

These include the following:

  • Vibration protection
  • Sharp profiles
  • Fast, simple, and safe installation
  • Enhances energy savings
  • Increased durability
  • Different color variation
  • Resistant to dust and other environmental conditions
  • Highly precise and quality designs
  • Choice variation of the ergonomic
  • Suitable thermal management
  • Minimal maintenance and service costs
  • Thermal protection
  • Regulated voltage drivers for specific items

How Does Aluminum Enclosures And Die Cast Housing Compare?

Aluminum enclosure and aluminum die cast housings are somehow alike.

 Aluminum enclosure

aluminum enclosure

They are both made via the die casting process for many reasons.

Also, you can have aluminum enclosures with mounting openings that accept circuits and covers that protects it from humidity.

die cast housing

die cast housing

For all your die cast housing from China, Inox offers a perfect solution for you – contact us now.

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