Workshop with Helbling Technik Wil AG: Die Casting in Focus
At ALUWAG in Niederbüren, knowledge exchange recently took center stage. Together with representatives from Helbling Technik Wil AG, we held a workshop that focused intensively on die casting—from the fundamentals to the challenges of serial production.
What is die casting?
Die casting is a high-precision manufacturing process in which molten metal is forced into a steel mold under high pressure. The process produces parts with excellent dimensional accuracy, good surface finish, and complex geometries. It is particularly cost-effective for medium to very large production runs, but it can also be suitable for smaller series.
Advantages and limitations of the process
Die casting offers clear advantages:
- High dimensional accuracy and surface quality
- Cost-efficiency for larger series
- Ability to integrate complex geometries and functions
- Short cycle times
However, certain limitations must also be taken into account. Typical challenges include:
- High tool costs during the initial phase
- Restricted wall thicknesses (too thin or too thick can be problematic)
- Requirements regarding demouldability
- Consideration of gas porosity, shrinkage cavities, and stresses when designing
What matters
Successful die-casting development begins long before the first serial production run. Early analysis is crucial:
- Is the part geometry suitable for casting?
- Which alloy is appropriate for the required function and load?
- How can the tool concept and process control be coordinated?
Only through close collaboration between design, toolmaking, and process expertise can parts be developed that are economical and reliable in series production.
A big thank you to our internal organizers Damian Föllmi and Thomas Bottlang for leading the training, and to the participants from Helbling Technik Wil AG: Daniel Soller, Alain Erni, Martin Rebmann, Michael Bachmann, Larry Bürge, Oliver Schwyter, Roman Schneider and Marco Bernegger.
The joint exchange demonstrated how important it is to discuss the potential and limits of die casting early on — as the foundation for successful projects.