Il costo di lavorazione della pressofusione si riferisce alla spesa totale di produzione delle parti pressofuse, riguardante l’approvvigionamento dei materiali, funzionamento dell'apparecchiatura, uso dello stampo, lavoro, e post-elaborazione. Varia ampiamente, ad esempio, le parti in lega di alluminio lavorate da una macchina da 200 tonnellate possono costare ~(0.45/kg, mentre le parti complesse in lega di rame con requisiti di alta precisione possono superare \)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: Core Components
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:
| Cost Component | Typical Proportion (Total Cost) | Calculation Method & Dettagli chiave | Benchmark di settore (Leghe di alluminio) |
| Material Cost | 50–60% | (Raw material price + waste loss rate × raw material price) × part weight- Waste loss rate: 8–15% (depends on process; higher for complex parts) | 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) ÷ hourly output- 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 |
| Mold Cost | 5–10% | (Mold manufacturing cost + maintenance cost) ÷ total production quantity- Mold life: 50,000–100,000 shots (aluminum alloy molds) | Simple mold: \(5,000–)10,000; complex mold (with sliders): \(20,000–)50,000 |
| Labor Cost | 8–12% | (Number of workers × hourly wage) ÷ hourly output- 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, sabbiatura, placcatura, or heat treatment- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Sbavatura: \(0.05–)0.1/kg; sabbiatura + placcatura: \(0.5–)1.2/kg |
2. Key Pricing Models for Die Casting Processing
Manufacturers use 2 main pricing models to calculate costs—each suitable for different scenarios. The table below compares their pros, contro, e casi d'uso ideali:
| Pricing Model | Calculation Formula | Vantaggi | Disadvantages | Ideale per |
| Equipment Tonnage-Based Pricing | Cost per kg = Base rate (per tonnage) + material premium (if using non-aluminum alloys)- Esempio: 200-ton machine: \(0.45/kg; 300-ton machine: \)0.65/kg | Semplice, fast calculation; easy for customers to understand | Ignores part complexity; may overcharge for simple parts | Large-batch, parti semplici (per esempio., staffe automobilistiche, hardware di base) |
| Itemized Costing (Precision Quotation) | Total cost = Material cost + equipment cost + costo dello stampo + labor cost + post-processing cost + profit margin (10–15%) | Accurate; reflects part-specific requirements; fair for both parties | Time-consuming; requires detailed part information (disegni, materiali) | Complesso, parti di alta precisione (per esempio., componenti di dispositivi medici, parti aerospaziali) |
3. Core Factors Influencing Die Casting Processing Cost
Multiple factors cause cost fluctuations—some can increase expenses by 30% o più. Below is a detailed analysis of 6 key factors with quantitative impacts:
UN. Tipo materiale (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Leghe di alluminio: Lowest cost (\(2.7–)3.45/kg material cost); facile da elaborare; ideal for most general parts.
- Leghe di zinco: Slightly higher cost (\(3.5–)4.2/kg material cost); good for small, parti precise (per esempio., alloggiamenti per l'elettronica).
- Leghe di rame: High cost (\(8–)10/kg material cost); requires higher temperature and pressure; used for heat-conducting parts (per esempio., dissipatori di calore).
- Leghe di magnesio: Premium cost (\(6–)7.5/kg material cost); lightweight but requires strict safety measures (flammable); used in aerospace/automotive lightweight parts.
B. Part Complexity & Progetto
Complex designs increase mold, lavoro, and post-processing costs:
- Structural Complexity: Parts with sliders, hydraulic core pulling, or insert installation add 20–50% to mold cost. Per esempio, a part with 2 sliders costs 30% more than a simple part of the same weight.
- Wall Thickness: Uneven wall thickness (ratio >3:1) reduces production efficiency by 15–25% (more rework needed), increasing labor and equipment costs.
- Precision Requirements: Tolerances tighter than ±0.1mm require precision machining, aggiungendo \(0.3–)0.8/kg to post-processing cost.
C. Order Volume (Critical for Cost Reduction)
Larger batches lower unit costs due to economies of scale:
- Piccoli lotti (<10,000 parti): High unit cost—mold cost is spread over fewer parts. Per esempio, UN \(10,000 mold for 5,000 parts adds \)2/part to the cost.
- Medium Batches (10,000–50,000 parts): Balanced cost—mold and equipment costs are spread reasonably; manufacturers may offer 5–10% discounts.
- Grandi lotti (>50,000 parti): Lowest unit cost—automation is feasible, labor costs drop, and material suppliers offer volume discounts (5–15% off raw material prices).
D. Mold Condition & Manutenzione
Poor mold condition increases rework and scrap rates, driving up costs:
- New Molds: Low scrap rate (<2%); no extra maintenance cost in the first 10,000 shots.
- Worn Molds: Scrap rate rises to 5–8%; require monthly maintenance (\(200–)500/muffa) to fix gaps or surface damage.
- Customer-Supplied Molds: If the mold needs debugging (per esempio., adjusting core position) or overhaul (per esempio., replacing worn components), additional costs of \(500–)2,000 may apply.
E. Post-Processing Requirements
Additional operations significantly increase costs—each step adds 5–15% to the total:
| Post-Processing Step | Cost Impact (Per kg Part) | Scopo |
| Sbavatura (manuale) | \(0.05–)0.1 | Rimuovere gli spigoli vivi |
| Lavorazione CNC | \(0.8–)2 | Achieve high precision (±0,05 mm) |
| Sabbiatura | \(0.2–)0.4 | Improve surface roughness (Ra <1.6µm) |
| Placcatura (chrome/nickel) | \(0.8–)1.5 | Enhance corrosion resistance and aesthetics |
| Trattamento termico (T6) | \(0.3–)0.6 | Increase tensile strength (from 200MPa to 300MPa+) |
F. Regional Cost Differences
Labor, electricity, and rent vary by region, affecting overall costs:
- North America/Europe: High costs—electricity (\(0.15–)0.25/kWh), lavoro (\(15–)25/ora); total cost per kg part: \(4–)6.
- Asia (Cina, Vietnam): Lower costs—electricity (\(0.05–)0.1/kWh), lavoro (\(5–)10/ora); total cost per kg part: \(2–)4.
- South America: Medium costs—electricity (\(0.1–)0.15/kWh), lavoro (\(8–)12/ora); total cost per kg part: \(3–)5.
4. Guida pratica: How to Get an Accurate Quotation & Control Costs
To avoid overpaying and ensure cost transparency, follow these 4 passi:
Fare un passo 1: Prepare Detailed Information for Manufacturers
Provide 3 key pieces of data to get a precise quote:
- 2D/3D Drawings: Include dimensions, tolleranze (per esempio., ±0,1 mm), and structural details (per esempio., number of sliders).
- Material Specifications: Clarify alloy type (per esempio., A380 aluminum, ONERI 5 zinco) and quality standards (per esempio., ASTM, ISO).
- Order Details: Annual purchase volume, delivery schedule, and post-processing requirements (per esempio., “need sandblasting + T6 heat treatment”).
Fare un passo 2: Compare Quotations Smartly
Don’t just choose the cheapest—evaluate 5 factors:
- Cost Breakdown: Ask for a detailed breakdown (materiale, attrezzatura, muffa, ecc.) to check for hidden fees.
- Capacità dell'attrezzatura: Ensure the manufacturer has machines matching your part’s needs (per esempio., 300-ton machine for large parts).
- Quality Certifications: Look for ISO 9001 (qualità) or IATF 16949 (automobilistico) to avoid rework costs from poor quality.
- Tempi di consegna: 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.
Fare un passo 3: Negotiate for Cost Savings
Use these 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).
- Ottimizzazione della progettazione: Work with the manufacturer to simplify designs (per esempio., reduce sliders, balance wall thickness) to cut mold and process costs by 15–20%.
Fare un passo 4: Monitor Costs During Production
Track 3 key metrics to avoid cost overruns:
- Scrap Rate: Keep it <3% (media del settore); higher rates mean wasted materials and labor.
- Mold Maintenance Frequency: Schedule maintenance every 10,000 shots to prevent unexpected downtime (costi \(500–)2,000/ora).
- Material Waste: 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
Alla tecnologia Yigu, we believe cost control in die casting is about balancing precision, qualità, and efficiency—not just cutting expenses. For automotive clients, our itemized costing model (con 100% transparent breakdowns) and design optimization services reduced their total costs by 18%. For medical device manufacturers, we use shared molds (per piccoli lotti) to lower mold cost per part by 40%, while maintaining ISO 13485 standard di qualità.
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.
Domande frequenti
- Why does the same part have different quotes from different manufacturers?
Quotes vary due to 4 factors: 1) Equipment efficiency (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?
Per piccoli lotti (<10,000 parti), mold cost is a major factor. Per esempio, UN \(10,000 mold for 5,000 parts adds \)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) or short-life molds (più economico, per <5,000 shots).
- Can post-processing be skipped to save costs?
It depends on the part’s use: 1) Non-visible, non-load-bearing parts (per esempio., internal brackets) can skip sandblasting/plating (salva \(0.5–)1.2/kg); 2) Visible parts (per esempio., consumer electronics housings) need surface treatment to avoid aesthetics issues; 3) Load-bearing parts (per esempio., parti strutturali automobilistiche) require heat treatment (cannot skip—this ensures strength and safety). Skipping necessary post-processing leads to higher defect rates and long-term costs.