Product designers who want to consider the best method for their products or components should always keep the process in mind to get the best results. The two most common methods used by manufacturers are injection molding and die casting. However, which one is more convenient? Let's compare die casting and injection molding in detail to understand the significant differences.

Die Casting

Die casting is a process in which metal is melted and poured into a mold cavity under high pressure to solidify. Die casting is suitable for manufacturing complex designs and usually uses materials such as zinc, aluminum, copper, etc.

Injection Molding

Injection molding is the process of injecting liquid material into a mold under high pressure. The liquid then cools and forms a solid shape of the desired component.

Tools and Costs

Due to the simplicity of the process, casting molds do not require additional tools. This results in low tooling costs for the entire manufacturing process. In addition, the mold can be used as an open mold, closed mold, and compression mold, which provides flexibility in product design.

On the other hand, the high pressure and high temperature costs involved in the injection molding process may be higher than casting. The tools for the injection molding process are closed metals with complex structures and require expensive finishing and machining to properly regulate the temperature.

Therefore, die casting is often a great solution for low-budget projects.

Materials used in the process

This is the main difference between die casting and injection molding processes. The die casting process uses raw materials, while injection molding uses plastics and polymers.

Advantages

Advantages of die casting

Precise shapes and tighter tolerances

Stronger designs and more stable structures

More stable and heat-resistant than injection molded designs

Complete resistance to UV rays and weather changes

Suitable for complex designs and shapes

Advantages of injection molding

Plastic injection molded parts are cheaper than metal parts

Flexible to adapt to a variety of plastic materials

Fillers can be injected to increase material strength

Parts made using plastic injection molds are good electrical insulators

Surface treatment and application

In most cases, the end result of die casting does not require additional operations, which makes it ideal for part manufacturing. However, additional finishing can be done to give the part an aesthetic appearance. On the other hand, injection molded parts may more frequently require additional finishing, including deburring, cleaning, de-gating, and decoration.

In terms of application, die casting is ideal for manufacturing small parts and industrial or commercial components such as automotive parts, hardware, sinks, faucets, etc. On the other hand, injection molding is used to make large products such as toys, spools of thread, machine parts, hair combs, tables, and other plastic products.