Die-casting mold design directly determines the final product’s performance. The mold not only defines the geometry, but also influences thermal balance, pressure distribution, material flow, and exhaust behavior. A standard mold consists of a fixed half and a moving half, complemented with runner structures, cooling circuits, exhaust channels, and ejection mechanisms.
The runner system is usually the first design priority. The flow channel must be structured so molten metal enters the cavity quickly and uniformly. Incorrect runner layout leads to turbulence, air entrapment, cold shuts, or incomplete filling. To prevent premature solidification, engineers often place the gate at locations allowing directional solidification and improved density.
Exhausting the mold cavity is crucial. If gases cannot escape efficiently, porosity, blowholes, and structural defects emerge. Modern molds integrate venting grooves, vacuum channels, and micro-exhaust pins to ensure stable filling.
Temperature control significantly affects part consistency. Too high a temperature causes sticking, shrinkage defects, or deformation; too low a temperature slows material flow and creates cold-shut marks. Therefore, balanced cooling channels, heating zones, and external temperature controllers are often used to maintain thermal stability. Some molds now apply intelligent thermal modules that adjust mold temperatures in real-time through monitoring data.
Ejection mechanisms must also distribute force evenly. Improper ejection causes part warping, cracking, or crushing. To avoid this, multiple ejector pins or block ejectors are commonly adopted, and for thin-wall or fragile structures, pneumatic ejection is used.
With ongoing digitalization, simulation-based mold engineering is now mainstream. Designers apply CFD flow analysis, pressure profile simulations, mold temperature mapping, and structural force analysis before mold fabrication, reducing testing cycles and development risk.
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