Die casting processing cost refers to the total expense of manufacturing die cast parts, covering material procurement, equipment operation, mold use, Arbeit, und Nachbearbeitung. It varies widely—for example, aluminum alloy parts processed by a 200-ton machine may cost ~\(0.45/kg, while complex copper alloy parts with high-precision requirements can exceed \)5/kg. This huge gap stems from multiple interrelated factors. But what exactly makes up the cost? How do different factors affect the final price? And how can you get an accurate quotation to control costs? This article answers these questions with detailed data and practical guidance.
1. Breakdown of Die Casting Processing Cost: Kernkomponenten
Die casting processing cost is not a single figure—it consists of 5 mutually influencing components. The table below details each part, its proportion, and calculation basis:
| Kostenkomponente | Typischer Anteil (Gesamtkosten) | Calculation Method & Schlüsseldetails | Branchen -Benchmarks (Aluminiumlegierungen) |
| Materialkosten | 50–60 % | (Raw material price + waste loss rate × raw material price) × part weight- Abfallverlustrate: 8–15 % (depends on process; höher für komplexe Teile) | Raw aluminum price: \(2.5- )3/kg; total material cost per kg part: \(2.7- )3.45 |
| Equipment Operation Cost | 15–20 % | (Machine hourly energy consumption × electricity price + machine depreciation) ÷ Stundenleistung- Machine depreciation: Calculated over 8–10 years (200-ton machine: ~$80,000 initial cost) | 200-ton machine: \(0.15- )0.2/kg; 300-ton machine: \(0.25- )0.35/kg |
| Schimmelpilze | 5–10 % | (Kosten für die Herstellung der Form + Wartungskosten) ÷ Gesamtproduktionsmenge- Schimmelleben: 50,000–100.000 Schüsse (Formen aus Aluminiumlegierung) | Simple mold: \(5,000- )10,000; complex mold (with sliders): \(20,000- )50,000 |
| Labor Cost | 8–12 % | (Number of workers × hourly wage) ÷ Stundenleistung- Automation level affects labor needs: Fully automated lines need 1–2 workers/line; semi-automated need 3–5 | Hourly wage: \(15- )25; labor cost per kg part: \(0.12- )0.3 |
| Post-Processing Cost | 5–15 % | Cost of cutting, Sandstrahlen, Überzug, oder Wärmebehandlung- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Enttäuschung: \(0.05- )0.1/kg; Sandstrahlen + Überzug: \(0.5- )1.2/kg |
2. Key Pricing Models for Die Casting Processing
Hersteller verwenden 2 main pricing models to calculate costs—each suitable for different scenarios. The table below compares their pros, Nachteile, und ideale Anwendungsfälle:
| Pricing Model | Calculation Formula | Vorteile | Nachteile | Ideal für |
| Equipment Tonnage-Based Pricing | Cost per kg = Base rate (per tonnage) + material premium (if using non-aluminum alloys)- Beispiel: 200-ton machine: \(0.45/kg; 300-ton machine: \)0.65/kg | Einfach, fast calculation; easy for customers to understand | Ignores part complexity; may overcharge for simple parts | Large-batch, einfache Teile (Z.B., Kfz -Klammern, Grundlegende Hardware) |
| Itemized Costing (Precision Quotation) | Total cost = Material cost + equipment cost + Schimmelpilze + Arbeitskosten + post-processing cost + profit margin (10–15 %) | Accurate; reflects part-specific requirements; fair for both parties | Zeitaufwendig; requires detailed part information (Zeichnungen, Materialien) | Komplex, Hochvorbereitete Teile (Z.B., Komponenten für medizinische Geräte, Luft- und Raumfahrtteile) |
3. Core Factors Influencing Die Casting Processing Cost
Multiple factors cause cost fluctuations—some can increase expenses by 30% oder mehr. Below is a detailed analysis of 6 key factors with quantitative impacts:
A. Materialtyp (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Aluminiumlegierungen: Niedrigste Kosten (\(2.7- )3.45/kg material cost); leicht zu verarbeiten; ideal for most general parts.
- Zinklegierungen: Slightly higher cost (\(3.5- )4.2/kg material cost); good for small, präzise Teile (Z.B., Elektronikgehäuse).
- Kupferlegierungen: Hohe Kosten (\(8- )10/kg material cost); requires higher temperature and pressure; used for heat-conducting parts (Z.B., Kühlkörper).
- Magnesiumlegierungen: Premium cost (\(6- )7.5/kg material cost); lightweight but requires strict safety measures (flammable); used in aerospace/automotive lightweight parts.
B. Teilkomplexität & Design
Complex designs increase mold, Arbeit, und Nachbearbeitungskosten:
- Structural Complexity: Parts with sliders, hydraulic core pulling, or insert installation add 20–50% to mold cost. Zum Beispiel, a part with 2 sliders costs 30% more than a simple part of the same weight.
- Wandstärke: Ungleiche Wandstärke (Verhältnis >3:1) reduces production efficiency by 15–25% (more rework needed), increasing labor and equipment costs.
- Präzisionsanforderungen: Tolerances tighter than ±0.1mm require precision machining, Hinzufügen \(0.3- )0.8/kg to post-processing cost.
C. Bestellvolumen (Critical for Cost Reduction)
Larger batches lower unit costs due to economies of scale:
- Kleine Chargen (<10,000 Teile): High unit cost—mold cost is spread over fewer parts. Zum Beispiel, A \(10,000 mold for 5,000 parts adds \)2/part to the cost.
- Medium Batches (10,000–50.000 Teile): Ausgewogene Kosten – Formen- und Ausrüstungskosten werden angemessen verteilt; Hersteller können 5–10 % Rabatt anbieten.
- Große Chargen (>50,000 Teile): Niedrigste Stückkosten – Automatisierung ist machbar, Arbeitskosten sinken, und Materiallieferanten bieten Mengenrabatte an (5–15 % Rabatt auf die Rohstoffpreise).
D. Mold Condition & Wartung
Ein schlechter Formzustand erhöht die Nacharbeits- und Ausschussrate, Kosten fahren:
- Neue Formen: Geringe Ausschussrate (<2%); Im ersten Fall fallen keine zusätzlichen Wartungskosten an 10,000 Schüsse.
- Abgenutzte Formen: Ausschussquote steigt auf 5–8 %; erfordern eine monatliche Wartung (\(200- )500/Schimmel) um Lücken oder Oberflächenschäden zu beheben.
- Vom Kunden bereitgestellte Formen: Wenn die Form debuggt werden muss (Z.B., adjusting core position) or overhaul (Z.B., replacing worn components), additional costs of \(500- )2,000 may apply.
E. Nachbearbeitungsanforderungen
Additional operations significantly increase costs—each step adds 5–15% to the total:
| Nachbearbeitungsschritt | Kostenauswirkungen (Per kg Part) | Zweck |
| Enttäuschung (Handbuch) | \(0.05- )0.1 | Scharfe Kanten entfernen |
| CNC -Bearbeitung | \(0.8- )2 | Achieve high precision (± 0,05 mm) |
| Sandstrahlen | \(0.2- )0.4 | Improve surface roughness (Ra <1.6μm) |
| Überzug (chrome/nickel) | \(0.8- )1.5 | Enhance corrosion resistance and aesthetics |
| Wärmebehandlung (T6) | \(0.3- )0.6 | Increase tensile strength (from 200MPa to 300MPa+) |
F. Regional Cost Differences
Arbeit, Strom, and rent vary by region, affecting overall costs:
- North America/Europe: High costs—electricity (\(0.15- )0.25/kWh), Arbeit (\(15- )25/Stunde); total cost per kg part: \(4- )6.
- Asien (China, Vietnam): Lower costs—electricity (\(0.05- )0.1/kWh), Arbeit (\(5- )10/Stunde); total cost per kg part: \(2- )4.
- South America: Medium costs—electricity (\(0.1- )0.15/kWh), Arbeit (\(8- )12/Stunde); total cost per kg part: \(3- )5.
4. Praktischer Leitfaden: How to Get an Accurate Quotation & Control Costs
To avoid overpaying and ensure cost transparency, Folgen Sie diesen 4 Schritte:
Schritt 1: Prepare Detailed Information for Manufacturers
Provide 3 key pieces of data to get a precise quote:
- 2D/3D Drawings: Include dimensions, Toleranzen (Z.B., ± 0,1 mm), and structural details (Z.B., number of sliders).
- Materialspezifikationen: Clarify alloy type (Z.B., A380-Aluminium, Lädt 5 Zink) and quality standards (Z.B., ASTM, ISO).
- Order Details: Annual purchase volume, delivery schedule, and post-processing requirements (Z.B., “need sandblasting + T6 heat treatment”).
Schritt 2: Compare Quotations Smartly
Don’t just choose the cheapest—evaluate 5 Faktoren:
- Kostenaufschlüsselung: Ask for a detailed breakdown (Material, Ausrüstung, Schimmel, usw.) to check for hidden fees.
- Gerätefähigkeiten: Ensure the manufacturer has machines matching your part’s needs (Z.B., 300-ton machine for large parts).
- Qualitätszertifizierungen: Suchen Sie nach ISO 9001 (Qualität) or IATF 16949 (Automobil) to avoid rework costs from poor quality.
- Vorlaufzeit: Longer lead times may mean higher inventory costs; choose manufacturers with 2–4 week lead times for standard parts.
- After-Sales-Service: Check if they offer mold maintenance or defect replacement—this reduces long-term costs.
Schritt 3: Negotiate for Cost Savings
Verwenden Sie diese 3 strategies to lower costs without compromising quality:
- Volume Commitments: Promise annual volumes >50,000 parts to get 10–15% discounts on unit costs.
- Long-Term Partnerships: Sign 1–2 year contracts for stable pricing (avoids raw material price fluctuations).
- Designoptimierung: Work with the manufacturer to simplify designs (Z.B., reduce sliders, balance wall thickness) to cut mold and process costs by 15–20%.
Schritt 4: Monitor Costs During Production
Track 3 key metrics to avoid cost overruns:
- Schrottrate: Keep it <3% (Branchendurchschnitt); higher rates mean wasted materials and labor.
- Mold Maintenance Frequency: Schedule maintenance every 10,000 shots to prevent unexpected downtime (Kosten \(500- )2,000/Stunde).
- Materialverschwendung: Optimize part nesting (arrange multiple parts in one mold) to reduce waste loss rate from 15% to 8–10%.
5. Yigu Technology’s Perspective on Die Casting Processing Cost
Bei Yigu Technology, we believe cost control in die casting is about balancing precision, Qualität, and efficiency—not just cutting expenses. Für Automobilkunden, our itemized costing model (mit 100% transparent breakdowns) and design optimization services reduced their total costs by 18%. For medical device manufacturers, we use shared molds (für kleine Chargen) to lower mold cost per part by 40%, while maintaining ISO 13485 Qualitätsstandards.
We’re advancing two cost-saving innovations: 1) AI-driven process optimization (reduces scrap rate to <2% and energy consumption by 12%); 2) Modular mold design (allows mold components to be reused across parts, cutting mold cost by 25%). Our goal is to help clients get high-quality die cast parts at competitive prices—turning cost control into a competitive advantage.
FAQ
- Why does the same part have different quotes from different manufacturers?
Quotes vary due to 4 Faktoren: 1) Effizienz der Ausrüstung (newer machines have lower operation costs); 2) Regional labor/electricity prices; 3) Quality standards (ISO-certified manufacturers charge more for better quality); 4) Mold reuse (manufacturers with existing similar molds offer lower quotes). Always ask for a cost breakdown to compare apples to apples.
- How much does mold cost affect the unit price of small-batch parts?
Für kleine Chargen (<10,000 Teile), mold cost is a major factor. Zum Beispiel, A \(10,000 mold for 5,000 parts adds \)2/part to the unit cost—this can double the total price. To reduce this impact, ask about shared molds (split mold cost with other clients) oder kurzlebige Formen (billiger, für <5,000 Schüsse).
- Can post-processing be skipped to save costs?
It depends on the part’s use: 1) Non-visible, nicht tragende Teile (Z.B., Interne Klammern) can skip sandblasting/plating (rettet \(0.5- )1.2/kg); 2) Sichtbare Teile (Z.B., Gehäuse für Unterhaltungselektronik) need surface treatment to avoid aesthetics issues; 3) Tragende Teile (Z.B., Automobilstrukturteile) require heat treatment (cannot skip—this ensures strength and safety). Skipping necessary post-processing leads to higher defect rates and long-term costs.