Die casting processing cost refers to the total expense of manufacturing die cast parts, covering material procurement, equipment operation, mold use, труд, и пост-обработка. It varies widely—for example, aluminum alloy parts processed by a 200-ton machine may cost ~\(0.45/кг, while complex copper alloy parts with high-precision requirements can exceed \)5/кг. 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 (Общая стоимость) | Calculation Method & Ключевые детали | Отраслевые тесты (Алюминиевые сплавы) |
| Стоимость материала | 50–60% | (Raw material price + waste loss rate × raw material price) × part weight- Waste loss rate: 8–15% (depends on process; выше для сложных частей) | Raw aluminum price: \(2.5- )3/кг; 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/кг; 300-ton machine: \(0.25- )0.35/кг |
| Стоимость плесени | 5–10% | (Mold manufacturing cost + maintenance cost) ÷ total production quantity- Жизнь пресс-формы: 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 |
| Стоимость постобработки | 5–15% | Cost of cutting, песчаная обработка, покрытие, или термообработка- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Выслушивание: \(0.05- )0.1/кг; песчаная обработка + покрытие: \(0.5- )1.2/кг |
2. Key Pricing Models for Die Casting Processing
Производители используют 2 main pricing models to calculate costs—each suitable for different scenarios. The table below compares their pros, минусы, и идеальные варианты использования:
| Pricing Model | Calculation Formula | Преимущества | Недостатки | Идеально подходит для |
| Equipment Tonnage-Based Pricing | Cost per kg = Base rate (per tonnage) + material premium (if using non-aluminum alloys)- Пример: 200-ton machine: \(0.45/кг; 300-ton machine: \)0.65/кг | Простой, fast calculation; easy for customers to understand | Ignores part complexity; may overcharge for simple parts | Большая партия, Простые части (НАПРИМЕР., Автомобильные кронштейны, Базовое оборудование) |
| Itemized Costing (Precision Quotation) | Total cost = Material cost + Стоимость оборудования + Стоимость плесени + labor cost + post-processing cost + profit margin (10–15%) | Accurate; reflects part-specific requirements; fair for both parties | Кропотливый; requires detailed part information (рисунки, материалы) | Сложный, Высокие детали (НАПРИМЕР., Компоненты медицинского устройства, аэрокосмические части) |
3. Core Factors Influencing Die Casting Processing Cost
Multiple factors cause cost fluctuations—some can increase expenses by 30% или больше. Below is a detailed analysis of 6 key factors with quantitative impacts:
А. Тип материала (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Алюминиевые сплавы: Самая низкая стоимость (\(2.7- )3.45/kg material cost); Легко обрабатывать; ideal for most general parts.
- Цинковые сплавы: Slightly higher cost (\(3.5- )4.2/kg material cost); good for small, точные части (НАПРИМЕР., Электроника корпуса).
- Медные сплавы: Высокая стоимость (\(8- )10/kg material cost); requires higher temperature and pressure; used for heat-conducting parts (НАПРИМЕР., радиаторы).
- Магниевые сплавы: Premium cost (\(6- )7.5/kg material cost); lightweight but requires strict safety measures (flammable); used in aerospace/automotive lightweight parts.
Беременный. Часть сложности & Дизайн
Complex designs increase mold, труд, и стоимость постобработки:
- Структурная сложность: Parts with sliders, hydraulic core pulling, or insert installation add 20–50% to mold cost. Например, a part with 2 sliders costs 30% more than a simple part of the same weight.
- Толщина стены: Неровная толщина стенки (соотношение >3:1) reduces production efficiency by 15–25% (more rework needed), increasing labor and equipment costs.
- Точные требования: Tolerances tighter than ±0.1mm require precision machining, добавление \(0.3- )0.8/kg to post-processing cost.
В. Заказать объем (Critical for Cost Reduction)
Larger batches lower unit costs due to economies of scale:
- Маленькие партии (<10,000 части): High unit cost—mold cost is spread over fewer parts. Например, а \(10,000 mold for 5,000 parts adds \)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.
- Большие партии (>50,000 части): Lowest unit cost—automation is feasible, labor costs drop, and material suppliers offer volume discounts (5–15% off raw material prices).
Дюймовый. Mold Condition & Обслуживание
Poor mold condition increases rework and scrap rates, повышение затрат:
- New Molds: Low scrap rate (<2%); no extra maintenance cost in the first 10,000 выстрелы.
- Worn Molds: Scrap rate rises to 5–8%; require monthly maintenance (\(200- )500/форма) to fix gaps or surface damage.
- Customer-Supplied Molds: If the mold needs debugging (НАПРИМЕР., adjusting core position) or overhaul (НАПРИМЕР., Замена изношенных компонентов), additional costs of \(500- )2,000 может применяться.
Эн. Требования к постобработке
Additional operations significantly increase costs—each step adds 5–15% to the total:
| Поступ-обработка шага | Влияние стоимости (Per kg Part) | Цель |
| Выслушивание (руководство) | \(0.05- )0.1 | Удалите острые края |
| Обработка с ЧПУ | \(0.8- )2 | Achieve high precision (± 0,05 мм) |
| Песчаная обработка | \(0.2- )0.4 | Improve surface roughness (Раствор <1.6мкм) |
| Покрытие (chrome/nickel) | \(0.8- )1.5 | Enhance corrosion resistance and aesthetics |
| Термическая обработка (T6) | \(0.3- )0.6 | Increase tensile strength (from 200MPa to 300MPa+) |
Фон. Regional Cost Differences
Труд, электричество, and rent vary by region, affecting overall costs:
- North America/Europe: High costs—electricity (\(0.15- )0.25/kWh), труд (\(15- )25/час); total cost per kg part: \(4- )6.
- Азия (Китай, Вьетнам): Lower costs—electricity (\(0.05- )0.1/kWh), труд (\(5- )10/час); total cost per kg part: \(2- )4.
- South America: Medium costs—electricity (\(0.1- )0.15/kWh), труд (\(8- )12/час); total cost per kg part: \(3- )5.
4. Практическое руководство: How to Get an Accurate Quotation & Control Costs
To avoid overpaying and ensure cost transparency, Следуйте этим 4 шаги:
Шаг 1: Prepare Detailed Information for Manufacturers
Provide 3 key pieces of data to get a precise quote:
- 2D/3D Drawings: Include dimensions, допуски (НАПРИМЕР., ± 0,1 мм), and structural details (НАПРИМЕР., number of sliders).
- Материальные спецификации: Clarify alloy type (НАПРИМЕР., А380 алюминий, Нагрузки 5 цинк) and quality standards (НАПРИМЕР., Астм, Iso).
- Order Details: Annual purchase volume, delivery schedule, and post-processing requirements (НАПРИМЕР., “need sandblasting + T6 heat treatment”).
Шаг 2: Compare Quotations Smartly
Don’t just choose the cheapest—evaluate 5 factors:
- Стоимость разбивки: Ask for a detailed breakdown (материал, оборудование, форма, и т. д.) to check for hidden fees.
- Возможности оборудования: Ensure the manufacturer has machines matching your part’s needs (НАПРИМЕР., 300-ton machine for large parts).
- Качественные сертификаты: Ищите ISO 9001 (качество) or IATF 16949 (Автомобиль) to avoid rework costs from poor quality.
- Время выполнения: Longer lead times may mean higher inventory costs; choose manufacturers with 2–4 week lead times for standard parts.
- Послепродажная служба: Check if they offer mold maintenance or defect replacement—this reduces long-term costs.
Шаг 3: Negotiate for Cost Savings
Используйте их 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).
- Оптимизация дизайна: Work with the manufacturer to simplify designs (НАПРИМЕР., reduce sliders, balance wall thickness) to cut mold and process costs by 15–20%.
Шаг 4: Monitor Costs During Production
Track 3 key metrics to avoid cost overruns:
- Скорость лома: Keep it <3% (Среднее значение в отрасли); higher rates mean wasted materials and labor.
- Mold Maintenance Frequency: Schedule maintenance every 10,000 shots to prevent unexpected downtime (расходы \(500- )2,000/час).
- Материальные отходы: 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
В Yigu Technology, we believe cost control in die casting is about balancing precision, качество, and efficiency—not just cutting expenses. Для автомобильных клиентов, our itemized costing model (с 100% transparent breakdowns) and design optimization services reduced their total costs by 18%. For medical device manufacturers, we use shared molds (Для небольших партий) to lower mold cost per part by 40%, while maintaining ISO 13485 стандарты качества.
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.
Часто задаваемые вопросы
- 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?
Для небольших партий (<10,000 части), mold cost is a major factor. Например, а \(10,000 mold for 5,000 parts adds \)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 (дешевле, для <5,000 выстрелы).
- Can post-processing be skipped to save costs?
It depends on the part’s use: 1) Non-visible, ненесущие части (НАПРИМЕР., внутренние кронштейны) can skip sandblasting/plating (спасение \(0.5- )1.2/кг); 2) Видимые части (НАПРИМЕР., consumer electronics housings) need surface treatment to avoid aesthetics issues; 3) Запасные детали (НАПРИМЕР., Автомобильные структурные детали) require heat treatment (cannot skip—this ensures strength and safety). Skipping necessary post-processing leads to higher defect rates and long-term costs.