O custo de processamento de fundição sob pressão refere-se à despesa total de fabricação de peças fundidas sob pressão, cobrindo aquisição de materiais, operação do equipamento, uso de molde, trabalho, e pós-processamento. Varia muito – por exemplo, peças de liga de alumínio processadas por uma máquina de 200 toneladas podem custar ~(0.45/kg, enquanto peças complexas de liga de cobre com requisitos de alta precisão podem exceder \)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 & Key Details | Referências da indústria (Ligas de alumínio) |
| Custo de materiais | 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, jato de areia, chapeamento, ou tratamento térmico- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Rebarbação: \(0.05–\)0.1/kg; jato de areia + chapeamento: \(0.5–\)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, contras, e casos de uso ideais:
| Pricing Model | Calculation Formula | Vantagens | Disadvantages | Ideal para |
| Equipment Tonnage-Based Pricing | Cost per kg = Base rate (per tonnage) + material premium (if using non-aluminum alloys)- Exemplo: 200-ton machine: \(0.45/kg; 300-ton machine: \)0.65/kg | Simples, fast calculation; easy for customers to understand | Ignores part complexity; may overcharge for simple parts | Large-batch, peças simples (por exemplo, suportes automotivos, hardware básico) |
| Itemized Costing (Precision Quotation) | Total cost = Material cost + equipment cost + custo do molde + labor cost + post-processing cost + profit margin (10–15%) | Accurate; reflects part-specific requirements; fair for both parties | Time-consuming; requires detailed part information (desenhos, materiais) | Complexo, peças de alta precisão (por exemplo, componentes de dispositivos médicos, peças aeroespaciais) |
3. Core Factors Influencing Die Casting Processing Cost
Multiple factors cause cost fluctuations—some can increase expenses by 30% ou mais. Below is a detailed analysis of 6 key factors with quantitative impacts:
UM. Tipo de material (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Ligas de alumínio: Lowest cost (\(2.7–\)3.45/kg material cost); fácil de processar; ideal for most general parts.
- Ligas de Zinco: Slightly higher cost (\(3.5–\)4.2/kg material cost); good for small, peças precisas (por exemplo, caixas eletrônicas).
- Ligas de cobre: High cost (\(8–\)10/kg material cost); requires higher temperature and pressure; used for heat-conducting parts (por exemplo, dissipadores de calor).
- Ligas de magnésio: Premium cost (\(6–\)7.5/kg material cost); lightweight but requires strict safety measures (flammable); used in aerospace/automotive lightweight parts.
B. Part Complexity & Projeto
Complex designs increase mold, trabalho, and post-processing costs:
- Structural Complexity: Parts with sliders, hydraulic core pulling, or insert installation add 20–50% to mold cost. Por exemplo, 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, adicionando \(0.3–\)0.8/kg to post-processing cost.
C. Order Volume (Critical for Cost Reduction)
Larger batches lower unit costs due to economies of scale:
- Pequenos lotes (<10,000 peças): High unit cost—mold cost is spread over fewer parts. Por exemplo, um \(10,000 mold for 5,000 parts adds \)2/part to the cost.
- Medium Batches (10,000–50.000 peças): Balanced cost—mold and equipment costs are spread reasonably; manufacturers may offer 5–10% discounts.
- Grandes lotes (>50,000 peças): Lowest unit cost—automation is feasible, labor costs drop, and material suppliers offer volume discounts (5–15% off raw material prices).
D. Mold Condition & Manutenção
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/mofo) to fix gaps or surface damage.
- Customer-Supplied Molds: If the mold needs debugging (por exemplo, adjusting core position) or overhaul (por exemplo, substituição de componentes desgastados), 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) | Propósito |
| Rebarbação (manual) | \(0.05–\)0.1 | Remova bordas afiadas |
| Usinagem CNC | \(0.8–\)2 | Achieve high precision (±0,05 mm) |
| Jateamento de areia | \(0.2–\)0.4 | Improve surface roughness (Rá <1.6μm) |
| Chapeamento (chrome/nickel) | \(0.8–\)1.5 | Enhance corrosion resistance and aesthetics |
| Tratamento térmico (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), trabalho (\(15–\)25/hora); total cost per kg part: \(4–\)6.
- Ásia (China, Vietnam): Lower costs—electricity (\(0.05–\)0.1/kWh), trabalho (\(5–\)10/hora); total cost per kg part: \(2–\)4.
- South America: Medium costs—electricity (\(0.1–\)0.15/kWh), trabalho (\(8–\)12/hora); total cost per kg part: \(3–\)5.
4. Guia Prático: How to Get an Accurate Quotation & Control Costs
To avoid overpaying and ensure cost transparency, follow these 4 passos:
Etapa 1: Prepare Detailed Information for Manufacturers
Fornecer 3 key pieces of data to get a precise quote:
- 2D/3D Drawings: Include dimensions, tolerâncias (por exemplo, ±0,1 mm), and structural details (por exemplo, number of sliders).
- Material Specifications: Clarify alloy type (por exemplo, A380 aluminum, ENCARGOS 5 zinco) and quality standards (por exemplo, ASTM, ISO).
- Order Details: Annual purchase volume, delivery schedule, and post-processing requirements (por exemplo, “need sandblasting + T6 heat treatment”).
Etapa 2: Compare Quotations Smartly
Don’t just choose the cheapest—evaluate 5 factors:
- Cost Breakdown: Ask for a detailed breakdown (material, equipamento, mofo, etc.) to check for hidden fees.
- Capacidades do equipamento: Ensure the manufacturer has machines matching your part’s needs (por exemplo, 300-ton machine for large parts).
- Certificações de Qualidade: Procure ISO 9001 (qualidade) or IATF 16949 (automotivo) to avoid rework costs from poor quality.
- Tempo de espera: 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.
Etapa 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).
- Otimização de Projeto: Work with the manufacturer to simplify designs (por exemplo, reduce sliders, balance wall thickness) to cut mold and process costs by 15–20%.
Etapa 4: Monitor Costs During Production
Track 3 key metrics to avoid cost overruns:
- Taxa de sucata: Keep it <3% (média da indústria); higher rates mean wasted materials and labor.
- Mold Maintenance Frequency: Schedule maintenance every 10,000 shots to prevent unexpected downtime (custos \(500–\)2,000/hora).
- Desperdício de materiais: 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
Na tecnologia Yigu, we believe cost control in die casting is about balancing precision, qualidade, and efficiency—not just cutting expenses. Para clientes automotivos, our itemized costing model (com 100% transparent breakdowns) and design optimization services reduced their total costs by 18%. For medical device manufacturers, we use shared molds (para pequenos lotes) to lower mold cost per part by 40%, while maintaining ISO 13485 padrões de qualidade.
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.
Perguntas frequentes
- 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?
Para pequenos lotes (<10,000 peças), mold cost is a major factor. Por exemplo, um \(10,000 mold for 5,000 parts adds \)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 (mais barato, para <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 (por exemplo, internal brackets) can skip sandblasting/plating (salva \(0.5–\)1.2/kg); 2) Visible parts (por exemplo, consumer electronics housings) need surface treatment to avoid aesthetics issues; 3) Load-bearing parts (por exemplo, peças estruturais automotivas) require heat treatment (cannot skip—this ensures strength and safety). Skipping necessary post-processing leads to higher defect rates and long-term costs.