Design preperation for metal molding

[srosendal]

Hello everybody

I have designed two small metal pieces (approx 30x30 mm) currently in 3D design that I now want to prepare for production by casting/molding. They are both intended for mass production hence price is a big concern, even the very small designchanges that may lead to reduction of price. However my knowledge concerning metal casting/molding method is very limited and I therefore plan to consult some experts in this field.

But before I will contact a firm about this, it would be so nice to gain better understanding of the method myself, and possible eliminate the very most bad designed or esxpensive areas.

I therefore need some design guidelines, best practices, collected experiences, rules of thumb or the like about metal casting and molding of small pieces. The goal is to make the part as easy to mold and as cheap to mold. Any litterature/web references/videos etc. with useable guidelines are very much appreciated.

Thanks

PS Considerations for the parts could be about Roundings, Fillets, Holes, Threads, Distances to edges, Shrinkage, Material selection. I do not expect to be able to compete with experienced guys in this field, but just the basic understanding and elimination of flaws and errors would be very nice.

 

[Achy47]

Hello there,

As a scientist with experience in metal casting and molding, I would be happy to provide you with some design guidelines and best practices for your project. First and foremost, it is important to understand the differences between casting and molding. Casting involves pouring molten metal into a mold, while molding involves shaping a material (such as clay or plastic) around a pattern to create a mold.

One important consideration for metal casting is the design of the part itself. It is important to keep in mind that the shape of the part will affect the flow of molten metal into the mold. For example, sharp corners or edges may cause turbulence in the metal flow and lead to defects in the final product. It is best to avoid sharp corners and instead use rounded edges or fillets to promote a smooth flow of metal.

Another important factor to consider is the placement of holes and threads in the design. These features should be placed in areas that will not interfere with the casting process, as they can create complications during the molding stage. Additionally, it is important to leave enough distance between these features and the edges of the part to avoid any potential defects.

Shrinkage is another important factor to consider in the design of your parts. As the molten metal cools and solidifies, it will shrink slightly. This can cause warping or distortion in the final product if not accounted for in the design. It is important to consult with experts in the field to determine the appropriate amount of shrinkage to allow for and adjust your design accordingly.

Material selection is also a crucial aspect to consider in metal casting and molding. Different metals have different properties and will behave differently during the casting process. It is important to select a material that is suitable for your desired end product and that will be cost-effective for mass production.

In terms of resources, there are many literature and web references available that can provide you with more detailed guidelines and best practices for metal casting and molding. I would recommend consulting books or articles on the subject, as well as reaching out to experts in the field for their insights and advice.

I hope this information helps you gain a better understanding of metal casting and molding and allows you to make informed decisions in the design of your parts. Best of luck with your project!