With the increasing demand for high-quality and high-volume die cast parts, as well as the rising cost of die casting tools, Raidy, a high-pressure die casting mold manufacturer, has conducted practical research on 3D-printed die casting mold inserts.
In many production applications, the surface of the die casting mold insert gradually deteriorates during continuous operation. As the insert ages, its local cooling performance decreases, resulting in shrinkage porosity defects in specific areas of the die cast parts during later production stages. In some cases, the leak testing rejection rate can exceed 30%.
To maintain product quality, these inserts typically need to be replaced after only 20,000–30,000 shots, significantly increasing maintenance costs and reducing production efficiency.
Raidymold has extensive experience in providing customized die casting solutions. In one case, we developed two different solutions for a customer and helped them select the optimal option, achieving better performance while reducing overall costs.
Optimizing Cooling Channels Through Die Casting Simulation
Based on the analysis of MAGMA simulation results, the goal was to redesign the cooling channels of the die casting mold insert to improve insert durability while increasing production efficiency.
The simulation focused on the temperature field and temperature curves under different heat transfer coefficients (HTC) between the insert and the die cast part.
Since the material properties of the insert remained unchanged, the main variable was the heat transfer behavior between the aged insert surface and the casting, represented by the interface heat transfer coefficient (HTC).
Under identical process conditions, different HTC values were assigned between the die casting mold insert and the die cast part to analyze their influence on thermal behavior.
The simulation results showed that:
- As the interface heat transfer coefficient decreased, the temperature of the insert body also decreased.
- The temperature field and temperature curves provided valuable data for optimizing cooling channel designs in die casting dies.
3D Printed Die Casting Mold Inserts Improve Cooling Performance
With advanced 3D printing technology, Raidy overcame the limitations of traditional CNC machining methods used for cooling channel manufacturing in die casting moulds.
Compared with conventional cooling designs, 3D printed die casting mold inserts enable:
- Conformal cooling channel designs that follow the geometry of the casting area.
- Increased cooling surface area for improved heat dissipation.
- Faster and more uniform cooling of critical areas.
Comparison of Cooling Channel Designs
- Left: Traditional CNC-machined insert
- Right: 3D printed insert
Simulation results demonstrated that even as the insert gradually aged and the interface heat transfer coefficient decreased, the temperature of the 3D printed die casting mold insert remained nearly 50°C lower than the traditional CNC insert.
This proves that the optimized cooling design provides significantly better thermal performance compared with conventional die cast tooling solutions.
X-Ray Inspection Verification of Die Casting Quality Improvement
X-ray inspection was conducted to compare the casting quality before and after optimizing the die casting mold insert.
- Left side: Original die cast part
- Right side: Die cast part produced with the optimized insert
The inspection results showed that shrinkage porosity defects were significantly reduced after applying the optimized 3D printed insert.
Production Results: Lower Defect Rate and Longer Insert Life
In actual production, the implementation of 3D printed die casting mold inserts achieved significant improvements:
- Die cast part quality was greatly improved.
- Shrinkage porosity defects detected by inspection were significantly reduced.
- The leak testing rejection rate decreased from over 30% to below 2%.
- The service life of the insert increased to 50,000–60,000 shots.
Compared with traditional inserts that required replacement after 20,000–30,000 shots, the optimized die casting mold insert achieved more than double the service life, reducing tooling maintenance costs and improving production stability.
Mold Flow Analysis Accelerates Die Casting Mold Optimization
Through die casting simulation, Raidy can optimize cooling conditions for die casting dies and validate cooling channel designs before production.
The combination of simulation analysis and 3D printing technology provides a reliable solution for optimizing die casting moulds, improving thermal management, extending insert life, and enhancing production efficiency.
Optimizing Costs with Die Casting Inserts
Raidy developed two optimized high-pressure die casting mold solutions for a Malaysian client with an 80,000-cycle production requirement:
Option 1: Dual-Mold Strategy
Split the production requirement into two molds, each designed for approximately 40,000 cycles, reducing upfront tooling costs through structural optimization and load distribution.
Option 2: Replaceable Insert Design
Develop a modular mold solution with replaceable inserts in high-wear areas, reducing long-term maintenance costs and improving mold lifecycle value.
Final Choice:
The client selected Option 2: Replaceable Insert Design due to its better cost efficiency, maintenance flexibility, and long-term production benefits.
For more information, please see “How to Meet Your Requirements for Die Casting Molds within Your Budget?“
Conclusion
As a high-pressure die casting mold manufacturer, Raidy successfully optimized die casting mold inserts by combining RAIDY simulation with advanced 3D printing technology.
The optimized inserts delivered:
- Improved cooling performance.
- Reduced shrinkage porosity defects.
- A reduction in leak testing rejection rates from over 30% to below 2%.
- Extended insert life up to 50,000–60,000 shots.
This practical application demonstrates that advanced die casting mold insert optimization can significantly improve casting quality, increase tooling durability, and reduce manufacturing costs for high-volume die casting production.
FAQ
What is an insert in die casting?
A die casting mold insert is a replaceable component installed inside a die casting die to form specific areas of a casting. It is commonly used in high-wear areas to improve cooling performance, extend tool life, and reduce maintenance costs.
Why do die casting mold inserts need to be replaced?
During continuous production, die casting mold inserts experience thermal fatigue and surface aging, which reduces heat transfer efficiency. This can cause shrinkage porosity defects, higher rejection rates, and reduced casting quality.
How do 3D printed die casting mold inserts improve performance?
3D printed die casting mold inserts enable conformal cooling channels that cannot be achieved with traditional CNC machining. They improve heat dissipation, provide more uniform cooling, and help extend insert service life.
How much can a die casting mold insert improve tool life?
In Raidy’s application, optimized 3D printed inserts increased service life from 20,000–30,000 shots to 50,000–60,000 shots, achieving more than double the original lifespan.
How does Raidy help optimize die casting dies?
Through advanced die casting simulation, temperature fields and heat transfer conditions are analyzed to optimize cooling channel designs, improve casting quality, and enhance the performance of die casting dies and inserts.
