Brass and Aluminum High-Pressure Die Castings and Value-Added Services

Case Studies

Die Casting


On-Time Delivery Ensures Lower Costs

Problem: When a manufacturer of single-stroke engines didn’t receive delivery of aluminum die castings as scheduled, its machining centers and assembly line were shut down. Tooling issues at its die casting supplier had halted production, costing the manufacturer valuable resources. Moreover, castings were stuck in the die cast tooling, and the mold was unusable to make parts. As the factory sat idle waiting for castings, the manufacturer couldn’t ship orders to customers.

Solution: The customer transferred the existing tooling to Rheocast. We utilized our complete in-house tool shop to remove the stuck castings and retrofit the existing mold to fit into our die cast presses. We adjusted draft in several key locations to prevent castings from sticking in the cover half of the mold, and fine-tuned the shot profile to reduce porosity and non-fill defects that had plagued this job. We also implemented quality inspection at the die cast machine and began drilling a critical hole to ensure porosity reduction in-process.

Within one week of receiving the tooling, Rheocast hand-delivered parts to the manufacturer, getting the production line back up and running. Our improvements also greatly reduced fallout that had occurred after machining.

From now on, the manufacturer can count on Rheocast to deliver quality aluminum die castings on time as promised – reliability that saves time and money.