Die casting processing cost refers to the total expense of manufacturing die cast parts, covering material procurement, equipment operation, mold use, lavoro, e post-elaborazione. 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: 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:
| Componente di costo | Proporzione tipica (Costo totale) | Calculation Method & Dettagli chiave | Parametri di riferimento del settore (Leghe di alluminio) |
| Costo materiale | 50–60% | (Raw material price + waste loss rate × raw material price) × part weight- Waste loss rate: 8–15% (depends on process; più alto per parti complesse) | 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 |
| Costo della muffa | 5–10% | (Mold manufacturing cost + maintenance cost) ÷ total production quantity- Vita della muffa: 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 |
| Costo post-elaborazione | 5–15% | Cost of cutting, sabbiatura, placcatura, o trattamento termico- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Sfacciato: \(0.05- )0.1/kg; sabbiatura + placcatura: \(0.5- )1.2/kg |
2. Key Pricing Models for Die Casting Processing
I produttori usano 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 | Svantaggi | 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 + costo dell'attrezzatura + Costo della muffa + labor cost + post-processing cost + profit margin (10–15%) | Accurate; reflects part-specific requirements; fair for both parties | Richiede tempo; requires detailed part information (disegni, Materiali) | Complesso, parti ad alta precisione (PER ESEMPIO., componenti del dispositivo medico, 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 di materiale (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Leghe di alluminio: Costo più basso (\(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., Alloggi elettronici).
- Leghe di rame: Costo elevato (\(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. In parte complessità & 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.
- Spessore del muro: Spessore parete irregolare (rapporto >3:1) reduces production efficiency by 15–25% (more rework needed), increasing labor and equipment costs.
- Requisiti di precisione: Tolerances tighter than ±0.1mm require precision machining, Aggiunta \(0.3- )0.8/kg to post-processing cost.
C. Volume dell'ordine (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, Aumento dei costi:
- New Molds: Low scrap rate (<2%); no extra maintenance cost in the first 10,000 colpi.
- 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. Requisiti di post-elaborazione
Additional operations significantly increase costs—each step adds 5–15% to the total:
| Passaggio di post-elaborazione | Impatto dei costi (Per kg Part) | Scopo |
| Sfacciato (manuale) | \(0.05- )0.1 | Rimuovere i bordi affilati |
| MACCHING CNC | \(0.8- )2 | Achieve high precision (± 0,05 mm) |
| Sabbiatura | \(0.2- )0.4 | Migliora la ruvidità della superficie (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
Lavoro, elettricità, 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 & Controllare i costi
To avoid overpaying and ensure cost transparency, Segui questi 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).
- Specifiche materiali: Clarify alloy type (PER ESEMPIO., A380 aluminum, Carichi 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:
- Composizione dei costi: Ask for a detailed breakdown (materiale, attrezzatura, muffa, ecc.) to check for hidden fees.
- Capacità di attrezzatura: Ensure the manufacturer has machines matching your part’s needs (PER ESEMPIO., 300-ton machine for large parts).
- Certificazioni di qualità: Cerca iso 9001 (qualità) or IATF 16949 (automobile) 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.
- Servizio post-vendita: Check if they offer mold maintenance or defect replacement—this reduces long-term costs.
Fare un passo 3: Negotiate for Cost Savings
Usa questi 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 del design: 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:
- Tasso di rottami: 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).
- Spreco di materiale: 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. Per client automobilistici, 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 colpi).
- Can post-processing be skipped to save costs?
It depends on the part’s use: 1) Non-visible, parti non portanti (PER ESEMPIO., parentesi interne) can skip sandblasting/plating (salva \(0.5- )1.2/kg); 2) Parti visibili (PER ESEMPIO., consumer electronics housings) need surface treatment to avoid aesthetics issues; 3) Parti portanti (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.