For the last 45 years, NADCA has sponsored its International Die Casting Design Competition to showcase outstanding die cast designs while acknowledging the continuous contribution die casters provide to the manufacturing industry. As die castings become more complex, higher quality, lower cost, and more unique, it becomes important for die casters to be involved in the process early in the product’s design phase. A die casting is not a machined part, sand casting, or an extrusion. It is critical for die casters to effectively communicate to the designer requirements to make a quality casting. The winners of the 2019 International Die Casting Competition have exhibited a close relationship with their customer to produce castings that have a complex design, high quality, and ingenuity. These castings often expand the market for die casting and reduce the cost of the part compared to the previous manufacturing method.
Aluminum Die Casting Over 10 lbs.
2019 Winner: Ryobi Die Casting, USA
Award Nominee: Ryan Wilhelm
Function of the Part
Transmission housing for a semi-truck.
Previous Process to Produce Part
The high pressure die casing process utilizes vacuum, spot cooling, and thinner walls to reduce the cycle time by 50 percent to 75 percent, while keeping the same high level of quality. Die casting can also use core pins to form the 120 holes on the castings, instead of requiring a machining operation. The faster cycle time reduces the cost per unit. Also, more robotic automation can be utilized and inventory reduced.