In-house Tooling

Unlike many companies within our sector, Dyson Diecasting employs a dedicated toolmaking facility. This gives us the added advantage of being able to respond quickly to client modifications and production issues.

Our highly skilled technicians and tool makers can provide expert advice both internally, where we are engineering the tooling and externally when tooling is supplied from either the client or a third party. Our facilities include CNC machine centres, CNC spark erusion, high speed milling and full 3D modeling. We have the capability to provide design assistance specific to prototype tooling, which is then supported by production tooling and periodic maintenance schedules. This guarantees the integrity of the tooling for the life of a project, resulting in orders that meet clients’ budgets and delivery dates.

Die Construction

Dies, or die casting tooling, are made of alloy tool steels in at least two sections, the fixed die half, or cover half, and the ejector die half, to permit removal of castings. The ejector half usually contains the runners (passageways) and gates (inlets) that route molten metal to the cavity. Dies also include locking pins to secure the two halves, ejector pins to help remove the cast part, and openings for coolant and lubricant. When the die casting machine closes, the two die halves are locked and held together by the machine’s hydraulic pressure. The surface where the ejector and fixed halves of the die meet and lock is referred to as the “die parting line.” The total projected surface area of the part being cast, measured at the die parting line, and the pressure required of the machine to inject metal into the die cavity governs the clamping force of the machine.

Processes

  • Mould release agent is applied to the dies, and the machine closed.
  • A measured amount of molten metal is poured into the pouring sleeve.
  • The plunger moves forward at a pre-determined speed and pressure to force metal into the mould cavity.
  • Water/oil cooling channels solidify the metal before the die’s are opened.
  • Die opens, ejector plates move forward pushing the casting out of the cavity.
  • Removed either by hand or by robot.
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