For projects that demand reliable repeatability without the capital intensity of multi‑cavity HPDC, permanent mold casting (gravity die casting) offers a compelling balance of cost, finish and dimensional control. Our Poznan team designs custom permanent molds tailored to your geometry, volumes and functional tolerances—then pairs them with metrology and CNC machining for installation‑ready parts.
What “custom” really means (beyond a block of steel)
Architecture: mold base + cavity inserts + ejection + vents + optional chills; modular inserts accelerate ECOs and protect wear zones.
Thermal system: cooling lines and baffles designed to flatten temperature gradients, reduce shrinkage and stabilize cycle times.
Gating/overflow: engineered for laminar fill; simulation validates fill pattern and predicts hot spots.
Surface intent: we co‑design draft, texturing and ejector locations so cosmetic faces stay clean.
DFM & casting simulation integrated from day one
A simulation‑first workflow compresses development:
Concept & DFM: wall thickness harmony, rib strategy, generous radii; early ISO 8062 class targets with GD&T for datums/bores.
Casting simulation: fill + solidification; optimize gates/vents/chills; pre‑heat and pour‑time windows defined.
Tool build: modular inserts, vent accessibility, temperature sensor ports.
T0/T1: confirm flow, adjust minor features; set pour temperature and cycle time.
T2 + capability: SPC plan locked; leakage/pressure tests if required.
PPAP/FAI: full CMM reports, gage R&R, control plan.
Alloys & process window
Aluminum die casting alloys for GDC: Al‑Si families for fluidity and finish; Al‑Mg where strength/corrosion are critical.
For tiny, ultra‑detailed features, consider a hybrid: components in zinc die casting (Zamak/ZnAl) + aluminum GDC enclosure.
Pour temperature, mold pre‑heat, and cycle timing are tuned to balance fill and microstructure.
From prototype to small/medium series (without drama)
Bridge strategy: start with a single‑cavity permanent mold to verify function; add a second cavity or duplicate tool later as demand grows.
Change‑friendly: replaceable inserts around bosses/threads/sealing lands allow ECOs without full re‑cut.
CNC integration: datum scheme and machining allowances agreed at DFM; in‑process probing + CMM keep GD&T on target.
Defect prevention & inspection
GDC’s laminar fill slashes gas porosity risk; thermal balance + chills address shrinkage.
Casting defects control plan with checkpoints for vents, overflow cleaning and mold temperature.
Optional CT scanning on critical lots; leak testing (air decay/helium) for sealed parts.
Finishing & assembly options
Shot/vibe finishing, impregnation if seal integrity is mission‑critical, chromate/paint/powder, selective machining of gasket lands, marking/serialization, kitting/packaging for direct line feed.
Where custom permanent molds shine
Pump/compressor bodies, valve and manifold housings.
Machinery brackets and covers that need dimensional stability and clean as‑cast surfaces.
Medium‑volume industrial components where HPDC would be over‑capitalized.
Practical RFQ checklist for faster Polish lead times
Final 3D with draft & wall map; 2D with ISO 8062 class + GD&T on CTQs.
Alloy family, EAU and ramp plan; cosmetic/finish expectations.
Leak‑test parameters (if applicable); packaging spec.
Schedule a DFM/simulation review to lock gates/vents/chills before steel is cut.
Takeaway: Custom permanent molds give you the control of dedicated tooling with the agility small and medium series require. In Poznan/Greater Poland, we turn DFM + casting simulation into stable production—meeting tolerance, surface and delivery commitments while keeping TCO in check.