Die Casting advice (a little off-topic)

Tramway Guy · Feb 19, 2015

I am looking to have some die casting made for a large aluminum part (18" diameter and 5.5 lbs each). The part has been made previously, but the tooling is long gone and so is the company that made it. I have found a couple of companies that can do it. One wants to use tooling from China, but parts in USA; originally estimated $22500 for tooling and $17 per piece, based on 500 parts(about an 8-year supply. That one was pretty reasonable, so I asked for a firm quote and payment schedule. The quote came back at $86,000 for tooling, but the same $17 price for parts!
Now I have another company (in Indiana) who would quote whole shebang made in China, $18,000 for tooling and $27 per part. That is certainly within my budget, but I am a little hesitant to buy parts from China, but there are few if any domestic producers that will bother with small runs like this of large parts. I have been looking for a couple months.
Does anyone here have any experience with die castings made in China? Good or bad?
The part is not for tractor-related goods, in case you are wondering.

DLMKA · Feb 19, 2015

For that kind of volume I'd look for a permanent mold unless you need the detail you can get from a die casting. Die casting tooling is notoriously expensive and you always have porosity issues.

dr sportster · Feb 19, 2015

My friend has a patent on a doggie pooper scooper thing that is made in China and he had to get a customs warehouse to accept and release the goods to him. Which is an additional cost. He tried to have them made in USA but found the Americvan companies claiming they were making it for him here were actually sending it to China behind his back. Then he got a cease and desist order as it has been found he is violating a previous patent to his. But thats a whole other story.

Mike M · Feb 19, 2015

Well that's about the size of custom alum rims maybe you could get a quote for solid alum ones ? They can knock them out on a CNC.

ObsoElitist · Feb 19, 2015

I have had a lot of replica auto parts cast by Sinner Bros. in San Diego. Their main market is mausoleum supplies, but they will make whatever they can. www.sinnerbrothers.com

Den N Ms · Feb 19, 2015

Tramway,I would do some more checking around for pricing at different foundries.
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Robin Hood · Feb 19, 2015

Sheave wheels for a lift?

Bruce Dorsi · Feb 19, 2015

Without knowing any details, wouldn't sand-casting and machining cost a lot less than molds for die-casting ?

redtom · Feb 19, 2015

If sand casting would work we have a local aluminum foundry that does one-off and small lot castings here in Mich

ss55 · Feb 19, 2015

For less than 100 pieces per year, have you looked into investment casting (Lost-Wax Casting)? Close tolerances, high surface finish and low tooling costs are advantages, higher piece cost due to extra manual labor is a disadvantage.

Wile E · Feb 19, 2015

Would it make sense to machine the item out of a solid aluminum billet? 5.5 pounds is not much for an 18inch diameter detail. Is it 3/4 inch thick?

DR. EVIL · Feb 20, 2015

I've got over thirty years of purchasing experience, buying parts for manufacturing. Most of those years as a casting buyer with parts less than a fraction of a pound to 12,000# finished weight, all types of iron, steel, stainless, to Hastelloy. All types of processes from sand, investment, permanent mold, and centrifugal castings. All the suggestions given have merit, but the idea to machine the part out of aluminum billet would provide 500 pieces for the least total cost.

The problem with diecast material is that it's weak and brittle, and almost impossible to repair. About it's only redeeming value is it's cheap.

Die Casting advice (a little off-topic)

Tramway Guy

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DLMKA

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dr sportster

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Mike M

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ObsoElitist

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Den N Ms

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Robin Hood

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Bruce Dorsi

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redtom

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ss55

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Wile E

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DR. EVIL

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