Die Casting

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            [_data_accordion_title] => Die Casting Process at Goudsmit UK: Start to Finish
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Component Modelling

 	
Many of our clients do not have a full design capability. Goudsmit UK can produce 3D models, 2D tolerance drawings, analysis of fits, FEA analysis and advice on alloys and finishes as required. 
 	
A 3D model of the component is created. If only 2D drawings are available, Goudsmit UK will convert these into a detailed 3D model. Using this model, we define key tooling features such as gates, vents, split lines, cores, ejector pins, and surface finish.


 	
Die Manufacture and Initial Casting

 	
A precision die is manufactured based on the agreed design.
 	
Molten metal is injected into the die under high pressure by a hydraulic ram. Metal solidifies in the die, which then opens to eject the component using pins.


 	
Sample Inspection and Tool Adjustment

 	
Initial castings ("first-offs") are inspected for dimensional accuracy, surface finish, and casting defects (e.g., porosity, cold casting).
 	
Required modifications are made to the die based on inspection outcomes. Further samples are produced and inspected until the casting meets all quality specifications.


 	
Sample Approval and Production

 	
Final samples are submitted to the customer for approval with comprehensive QA documentation.
 	
Upon approval, Goudsmit UK carries out a pre-production batch followed by full-scale production.



 
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            [_data_accordion_title] => Finishing and Surface Treatments
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Die cast parts often show small marks or seams caused by how the metal is injected and released from the tool. These are normal and part of the process, but they can be reduced or improved through finishing.
What to Expect on a Die Cast Part:


 	

Gates and vents are needed to let metal in and air out — these will leave small marks.

 	

Ejector pins help push the part out of the tool — they also leave visible circles or dents.

 	

Flash is thin excess metal around split lines that appears where the tool separates.


How We Improve the Finish:


 	

Clipping removes the larger metal feed and vent points after casting. This can be done mechanically or hydraulically.

 	

Because casting alloys don’t break as cleanly as steel, some small leftover marks (called "witness") are normal.

 	

If a cleaner finish is needed, we can machine the area using CNC to smooth it out.


Surface Finishing Options:
After clipping, we can further improve the part’s appearance using:


 	

Shot blasting or tumbling to smooth sharp edges and reduce flash

 	

Powder coating to apply colour and cover minor marks

 	

Nickel plating or chromate coating for corrosion protection


Note: Die cast parts don’t anodise well, and over time the surface may darken from oxidation. A surface finish is recommended for appearance and protection.
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            [_data_accordion_title] => Post-Casting Machining and Design Considerations
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While die casting offers rapid, near-net-shape metal production, not all features can be formed in the die itself. Some must be machined after casting to achieve the required function or tolerance.
Design Limitations for Casting
Some features are better suited to post-cast machining, such as:


 	

Holes not aligned with the split line

 	

Parallel-sided features (draft is required for ejection)

 	

Threads, especially if the axis is not along the split line

 	

Undercuts or complex internal forms


CNC Machining Capabilities


 	

Goudsmit UK offers multi-axis CNC milling and turning to finish components to specification.

 	

CNC provides high repeatability and is used for nearly all post-cast machining.

 	

This enables tight tolerances and complex geometries that can’t be achieved through casting alone.


Insert Features and Strength Zones

 	

High-load features (e.g. tapped bosses) may require added strength.

 	

Press-fitting stainless steel inserts is often preferable to casting around them.

 	

Some components (e.g. motor shafts) can be cast around, depending on design.


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