Die Casting Prototyping and DFM Review: The First 7 Days
Day 0: what a useful enquiry contains
The fastest programmes share the same six items at the start: a 3D model in STEP, IGES or DXF; the annual volume and expected batch size; the alloy preference or a note that it is open; critical tolerances with locations - not a blanket tolerance across the drawing; the finishing requirement; and any mandatory standards such as RoHS, REACH or IATF 16949 documentation.
Missing any of these usually costs more time than it saves. A blanket tolerance, for instance, forces conservative quoting and expensive inspection everywhere instead of on the features that matter.
DFM review before any steel is cut
DFM (design for manufacture) is where cost is actually decided. Typical findings at this stage include draft angles that make ejection difficult, wall thickness transitions that create shrinkage porosity, radii that are too sharp for good metal flow, and parting line placement that puts cosmetic surfaces - or worse, sealing faces - exactly where flash forms.
None of these are fatal, but each is cheap to fix on a drawing and expensive to fix in a hardened tool. Where the geometry is gas-sensitive, this is also the point at which vacuum die casting is recommended, along with any features that will need five-axis CNC finishing rather than being cast to size.
Trial shots and what to measure first
The first trial establishes the process window rather than finished quality. Expect the initial parts to be used for flow analysis verification, porosity checks and fit-up against the mating parts; cosmetic and dimensional refinement follows once the window is stable.
We work to general tolerances of ±0.05 mm where specified, with five-axis CNC finishing and, where needed, vacuum die casting for gas-sensitive geometries. Prototype samples ship in about 7 days, volume production in 30 to 45 days after approval. Minimum order quantity starts from 100 pieces, with T/T 30% deposit and EXW, FOB, CIF or DDP terms available.
FAQ
How fast can I get a prototype?
Prototype samples are typically delivered in about 7 days, subject to geometry and alloy availability. Volume production runs 30 to 45 days after sample approval. Providing a complete drawing set and volume estimate at enquiry stage is the largest single factor in holding that schedule.
What drawing formats do you accept?
STEP, IGES and DXF are all accepted. A 3D solid model is preferred over a mesh format, because it allows direct tooling and simulation work without re-modelling.
Do you provide DFM feedback?
Yes, free of charge. Typical recommendations cover draft angles, wall uniformity, gate location, parting line placement and radii, and whether vacuum assistance or five-axis finishing is needed for the critical features.
What are MOQ, payment and shipping terms?
Minimum order quantity starts from 100 pieces. Payment is T/T with 30% deposit, L/C or PayPal. Trade terms available are EXW, FOB, CIF and DDP, so Incoterms can be matched to your existing freight arrangements.
All figures above refer to standard product data sheets; final confirmation is subject to written quotation.