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

Case Studies

Die Casting


Cost Savings Achieved by Redesigning Sand Casting Part as Die Casting Part

Problem: A manufacturer of geothermal power units experienced problems with a sand casting part. Issues included excess material, high casting cost, high machining costs and slow production time.

Solution: Rheocast engineers worked with the customer to help them redesign the part, converting it from a sand casting to a die casting component. The resulting part had thinner walls, required less machine stock, reduced machining costs and generated faster cycle times. The customer achieved substantial savings: machining time, casting weight and assembly time were all reduced by 83% on average. In addition, the Rheocast die casting component was part of an entirely American-made product. This project also received industry recognition, winning the International Die Casting Competition hosted by the North American Die Casting Association (NADCA).