Die Casting vs Injection Molding: The Pros and Cons
Before we go to the serious stuff, let’s put first things first. Let’s go right ahead and define die casting and injection molding. Die casting is a method of casting metal by using intense force. The raw material used in this process is metal and it is melted and forced into a steel mold. Once the material has hardened, it is cast out from the machine. The injection moulding process works in a very similar way except for the fact that instead of metal, plastic or polymers are used as raw materials for various products by plastic buckle manufacturers.
Die Casting vs Injection Molding: The Process
- Phase One: Before the steel mold is closed, it is sprayed with a lubricant. It regulates the temperature inside the dies and facilitates easy removal of finished product at the end of the process.
- Second Phase: Liquified metal is transferred into the die through extreme pressure, taking the form of the die.
- Third Phase: The mold is cooled by immersing or spraying it with cold water so that the casting can be easily taken out.
- Fourth phase: The cast is removed by opening the die.
The phases and types of injection moulding are very similar to die casting, except for the fact that plastic manufacturers use plastic or polymers instead of metal raw materials.
Die Casting vs Injection Molding: The Pros
Now that you are familiar on how both processes are done, you should know why die cast and plastic manufacturers love to use these two manufacturing processes.
- It is capable of producing commodities with excellent accuracy.
- The machines used in this process makes increased production rates possible.
- Due to its efficiency, the need for secondary machinery is reduced or even eliminated.
- Mass production of identical castings may be made by thousands!
- Manufacturing complex designs with increased tolerance levels is a reality.
- More commodities can be processed in a shorter span of time.
- More than one raw material can be used in the plastic injection molding machine.
- The process allows flexibility in design.
- Fillers may be used. These increase the strength of the product.
- Plastic injection molding machine produces very accurate finish products.
- Since the machine is very efficient, manual labor can be reduced.
The two manufacturing processes also have different types. When it comes to plastic injection mold, the conventional method is what we have discussed earlier. The following are the other types.
Types of Injection Moulding
- powder injection
- fusible core injection
Die Casting vs Injection Molding: The Cons
Just like any method of manufacturing, everything has its own set of cons and let’s get to the list.
- This manufacturing process is only limited to raw materials with high-fluidity elements.
- Just like injection molding, initial cost may be high.
- Casting must be lesser than 24 inches or 600 millimeters and weight must be around 30 grams.
- The expense for manual labor and waste materials are very minimal but initial investment for plastic injection molding machine or other equipment is rather high.
- Parts for various products like custom buckles must be designed accurately.
- The running costs have the potential to go up in any types of injection moulding.