Product designers who want to consider the best method for products or components should always keep the processes in mind for the best results. The two most common methods manufacturers use are injection molding and die casting. But, which is more convenient? Let us have a detailed comparison between die casting and injection molding to understand the significant difference.
DIE CASTING VS. INJECTION MOLDING: DIFFERENCES
Die casting is a process in which a metal is liquified in molten form and poured into a mold cavity under high pressure for solidification. Suitable for manufacturing complex designs die casting is usually done with zinc, aluminum, copper, etc.
Injection molding is when the material is injected into the mold under high pressure in a liquid form. The liquid then gets cool and comes out as solid shapes of the components required.
TOOLING & COST
Casting molds do not require additional tooling due to the simple process. This leads to low tooling costs for the overall manufacturing process. In addition, the mold can be used as an open, closed, and compressed mold, which provides flexibility while designing the products.
On the other hand, the high pressures and temperature involved in the injection molding process can cost higher than casting. The tools for the injection molding process are closed metal, which is complex and requires expensive finishing and machining to regulate the temperature properly.
As a result, die cast is often an excellent solution for low-budget projects.
MATERIALS USED FOR THE PROCESS
This is the main difference between die casting and injection molding processes. In die casting, the process is done with raw materials, while injection molding uses plastic and polymers.
DIE CASTING ADVANTAGES
- Accurate shape and tighter tolerance
- Stronger designs with a more stable structure
- More stable and heat resistant than injection molding designs
- Fully resistant to UV rays and weather changes
- Ideal for complex designs and shapes
INJECTION MOLDING ADVANTAGES
- Plastic injection molded parts are cheaper than metal parts
- Flexibility to accommodate various plastic materials
- Fillers can be injected to increase the strength of the material
- The pieces created with plastic injection molds are good electrical insulators
SURFACE FINISHING & APPLICATIONS
The final result of die casting does not need additional operations in most cases, which makes it ideal for component manufacturing. However, extra finishing can be done to make the part aesthetically appealing. On the other hand, injection moldings might need the additional finish more frequently, including deflashing, cleaning, degating, and decorating.
In applications, die casting is ideal for creating small parts and industrial or commercial components like auto parts, hardware, sink, faucets, etc. On the other hand, injection molding is used for fabricating large products like toys, wire spools, mechanical parts, hair combs, tables, and other plastic products.