The Diferences Between Injection Molding and Die Casting

There are two processing methods to make massive production or low volume production: injection molding and die casting. They are two different manufacturing processes that have significant differences in terms of materials, process, equipment, product characteristics, and other aspects.

1. Materials

Injection Molding:

It mainly uses plastic materials, including thermoplastics (PE, PP, PVC, etc.) and thermosetting plastics (phenolic resin, epoxy resin, etc.)

Die Casting:

It mainly uses metal materials, usually low-melting-point metals or alloys, such as aluminum , zinc , magnesium , etc.

2. Process

Injection Molding:

Plastic material feeding to the hopper then it is heated and melted into a fluid state, the molten plastic is injected into the mold cavity, after cooling and solidification, the molded product is removed.

Die Casting:

After the metal material is melting,the molten metal is quickly injected into the mold cavity, the desired shape is forming after cooling and solidification, finally the mold is opened, and the cast metal part is removed.

3. Equipment

Injection Molding:

Injection molding machines are including the hopper, screw, nozzle, mold mounting section, and control system.The size of the machine is selected based on the size and weight of the product, with small, medium, and large injection molding machines available.

Die Casting:

Die casting machines are including the melting furnace, injection mechanism, mold mounting section, and control system.There are two types of die casting machines: cold-chamber which suitable for metals with higher melting points. Hot-chamber is suitable for metals with lower melting points.

4. Product Characteristics

Injection Molding can produce products with high dimensional precision and tight tolerance, the product surface is smooth, complex surface textures and appearance designs can be achieved.

 The weight of product is light, and the mold cost is relatively low for small batch production, while the unit cost of the product is low. for mass production.

Die Casting can produce metal parts with high dimensional precision, although slightly lower than that of injection molding.The surface is relatively smooth, but not as delicate as that of injection molding products, and may require subsequent surface treatment.The product is relatively heavy, and the mold cost is high, but the unit cost of the product is low for mass production.

Injection Molding products

Die casting products

In summary, injection molding and die casting each have their own characteristics and applicable ranges. The choice of which process to use depends on factors such as the material requirements of the product, the complexity of its shape, production volume, and cost budget.

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