Stamping and die casting are both essential metalworking processes that rely on molds and pressure—but they are far from interchangeable. While casual observers might confuse them (thanks to shared terms like “mold” and “pressure”), their core principles, material states, and end products are fundamentally distinct. Для производителей, mixing them up can lead to costly mistakes: choosing stamping for a complex 3D part (which die casting excels at) or die casting for a thin flat panel (where stamping shines) wastes time, деньги, и ресурсы. Но что именно выделяет их? How do their workflows differ? And how do you choose the right one for your project? This article answers these questions with side-by-side comparisons, technical details, и реальные примеры.
1. Core Distinction: Material State & Molding Principle
The biggest divide between stamping and die casting lies in how they handle metal—one works with solid metal, the other with liquid. This single difference shapes every other aspect of the processes.
А. Штамповка: Solid-State Plastic Deformation
Stamping is a “cold working” process (no melting required) that transforms solid metal sheets/plates (НАПРИМЕР., сталь, алюминий) into desired shapes via mechanical force.
- Material Input: Solid metal blanks (толщина: 0.1–10mm for most applications; НАПРИМЕР., 1mm aluminum sheets for phone casings).
- Основной принцип: Uses the Пластическая деформация of solid metal. A press applies pressure (10–1000MPa) via a stamping die (punch + умирать), изгиб, растяжение, or cutting the metal without changing its volume.
- Ключевая черта: No phase change (metal stays solid throughout); the final part’s density matches the raw material (≥99.5% density).
Беременный. Умирать кастинг: Liquid Filling & Затвердевание
Die casting is a “hot working” process that melts metal into a liquid, then shapes it in a mold.
- Material Input: Расплавленный металл (НАПРИМЕР., aluminum alloy heated to 680–720°C, zinc alloy to 380–420°C).
- Основной принцип: Relies on fluid dynamics and solidification. Высокое давление (5–150MPa) injects liquid metal into a closed mold cavity; the metal cools and solidifies into the mold’s shape.
- Ключевая черта: Involves phase change (liquid → solid); the process requires precise control of temperature and flow to avoid defects like pores or shrinkage.
2. Сравнение бок о бок: Процесс, Оборудование & Products
To fully understand the gap between stamping and die casting, let’s break down their workflows, инструменты, and end products in a detailed table:
| Коэффициент сравнения | Штамповка | Умирать кастинг |
| Material Form | Solid metal sheets/plates (сталь, алюминий, медь) | Liquid metal alloys (алюминий, цинк, магний) |
| Molding Die Design | Simple two-part molds (punch + умирать); focuses on guidance and discharge (НАПРИМЕР., ejector pins for sheet removal). No need for temperature control. | Complex molds with runner systems (to guide liquid metal), exhaust grooves (to release gas), и охлаждающие каналы (контролировать затвердевание). Requires heat-resistant materials (НАПРИМЕР., H13 сталь). |
| Ключевое оборудование | Mechanical/hydraulic press (зажимная сила: 10–2000 тонн); no integrated heating. | Die casting machine (includes melting furnace, injection system, and mold temperature controller); зажимная сила: 50–4000 tons. |
| Process Steps | 1. Cut metal into blanks.2. Load blank into press.3. Apply pressure to deform metal.4. Eject finished part (no cooling step needed). | 1. Melt metal in a furnace.2. Inject liquid metal into mold under pressure.3. Cool metal to solidify.4. Open mold and eject part.5. Trim excess material (НАПРИМЕР., runner residues). |
| Время цикла | Быстрый (0.5–5 seconds/part for high-volume parts like beverage cans). | Умеренный (15–60 seconds/part; longer for thick-walled parts due to cooling time). |
| Product Characteristics | – Thin-walled, flat or shallow 3D shapes (max depth: 5× material thickness).- Равномерная толщина (Допуск ± 0,05 мм).- Dense structure (no pores); ideal for plating/painting. | – Сложные 3D -формы (глубокие полости, internal threads, тонкие стены до 0,5 мм).- Variable thickness (can have thick ribs for strength).- May have micro-porosity (fixed via vacuum casting or heat treatment). |
3. Сценарии приложения: Which Process Fits Which Part?
Stamping and die casting serve entirely different product needs. The table below maps each process to its ideal use cases, с реальными примерами:
| Промышленность | Ideal for Stamping | Ideal for Die Casting |
| Автомобиль | – Теловые панели (двери, капюшоны, крылья)- Fuel tank caps- Тормозные прокладки (steel backing plates) | – Engine blocks and cylinder heads- Королевки передачи- EV battery pack frames (complex 3D structures) |
| Потребительская электроника | – Phone/tablet back covers (плоский, thin aluminum sheets)- Laptop keyboard frames- TV mounting brackets | – 5G router housings (with internal ribs)- Headphone metal frames (intricate curves)- Силовой инструмент (impact-resistant 3D shapes) |
| Домашние приборы | – Refrigerator door panels- Washing machine drum lids- Microwave oven outer shells | – Air conditioner compressor housings- Blender motor brackets (with integrated cooling channels)- Dishwasher spray arms (пустой, complex flow paths) |
| Упаковка | – Aluminum beverage cans- Tin can lids- Metal food containers | – No—too simple for die casting; stamping is cheaper and faster. |
4. Common Misconceptions: Setting the Record Straight
Even experienced engineers sometimes mix up stamping and die casting. Below are three frequent myths and the facts to correct them:
Миф 1: “Both use molds and pressure—so they’re similar processes.”
Факт: Pressure serves opposite purposes. In stamping, pressure bends/stretches solid metal (changing shape, not state). In die casting, pressure pushes liquid metal into mold cavities (filling space, then solidifying). The mold designs also differ drastically: stamping dies need no cooling or runner systems, while die casting dies rely on these to avoid defects.
Миф 2: “Stamping can make complex 3D parts like die casting.”
Факт: Stamping is limited to shallow 3D shapes. Например, a stamping press can make a phone back cover (глубина: 10мм, толщина: 1мм), but it cannot make a phone’s middle frame (with internal slots, нить, and varying thicknesses)—that requires die casting. Stamping also needs multiple passes (НАПРИМЕР., 3–5 steps for a deep-drawn cup), while die casting makes complex parts in one cycle.
Миф 3: “Die casting parts are weaker than stamped parts.”
Факт: Это зависит от приложения. Stamped parts have dense, uniform structures (great for flat, load-bearing parts like brake pads). But die casting parts can be reinforced with thick ribs or internal supports (НАПРИМЕР., automotive steering knuckles) that stamped parts can’t match. With modern techniques like semi-solid die casting, die casting parts can reach tensile strengths of 300MPa—on par with stamped steel.
5. How to Choose Between Stamping and Die Casting
Follow this 3-step framework to pick the right process for your project:
Шаг 1: Analyze Part Geometry
- Выбирать штамповка если: The part is flat, тонкий (≤5 мм), or has shallow depth (depth ≤5× thickness). Примеры: панели, скобки, крышки.
- Выбирать умирать кастинг если: The part has complex 3D features (глубокие полости, internal threads, ребра) or variable thickness. Примеры: корпусы, Компоненты двигателя, структурные рамки.
Шаг 2: Evaluate Production Volume
- Высокий объем (>1 million parts/year): Stamping is cheaper and faster (НАПРИМЕР., банки для напитков).
- Medium volume (10,000–100,000 parts/year): Die casting is feasible (mold costs are spread over more parts).
- Low volume (<10,000 части/год): Stamping may be better (lower mold costs than die casting).
Шаг 3: Check Material & Потребности в производительности
- Материал: Stamping works with steel, алюминий, медь, and even plastics. Die casting is limited to non-ferrous alloys (алюминий, цинк, магний).
- Производительность: Need corrosion resistance or plating? Stamping’s dense surface is better. Need impact resistance for a 3D part? Die casting’s ribbed design excels.
6. Yigu Technology’s Perspective on Stamping vs. Умирать кастинг
В Yigu Technology, we see stamping and die casting as complementary tools—each solving unique manufacturing challenges. For clients needing high-volume flat parts (НАПРИМЕР., Автомобильные панели кузова), our automated stamping lines (with 1000-ton presses) achieve cycle times of 1.2 seconds/part and 99.8% yield. For clients requiring complex 3D parts (НАПРИМЕР., ЭВ -аккумуляторные корпусы), our die casting solutions (600-ton machines + vacuum systems) reduce porosity to <0.5% and meet IP68 waterproof standards.
We’re optimizing both processes: 1) Adding AI to stamping presses to adjust pressure in real time (reducing material waste by 12%); 2) Developing modular die casting molds that cut tooling costs by 30% for small-batch runs. Our goal is to help clients avoid “one-size-fits-all” choices—matching each part to the process that delivers the best quality, скорость, и стоимость.
Часто задаваемые вопросы
- Can a part be made with both stamping and die casting?
Yes—hybrid designs are common. Например, an automotive EV battery pack may use die casting for the complex 3D frame (to hold cells) and stamping for the flat top cover (to seal the pack). This combines die casting’s shape flexibility with stamping’s cost efficiency for flat parts.
- Which process has lower mold costs: stamping or die casting?
Stamping molds are cheaper. A simple stamping die for a flat bracket costs \(5,000- )15,000, while a die casting mold for a complex housing costs \(20,000- )50,000. Однако, die casting molds last longer (50,000–100,000 shots vs. 30,000–50,000 for stamping dies), so die casting becomes cheaper for high-volume parts.
- Is die casting better than stamping for lightweight parts?
Die casting is often better for lightweight 3D parts. Например, a die-cast aluminum EV battery frame weighs 20–30% less than a stamped steel frame (since die casting can add thin ribs for strength instead of using thick solid metal). Stamping is better for lightweight flat parts (НАПРИМЕР., thin aluminum phone covers), but it can’t match die casting’s weight savings for complex structures.