As a designer of a part that will be die cast, you must switch gears mentally when it comes to prototype casting. Do not assume that everything will be accomplished in the casting process. The question that isn’t asked may be the one that trips up the project.
For example: Should this seal groove be cast? Although seal grooves are readily cast in the die casting process, they are more cost-effectively machined in the prototype casting process.
Sometimes the right casting design decision is completely contrary to popular belief. For example: It is commonly accepted that fewer parts in an assembly generally means a lower production cost. That logic would stipulate that it is more cost-efficient to create one casting rather than two. But that theory does not always hold true. When you are struggling with the design for a complex part to make it work as one casting, you may experience the nagging thought that this should not be that difficult.
That nagging inner voice is telling you to try another approach. Once in a while it is more cost-efficient to change a design from a single complex casting into two simple castings. The question is, could that part have been successfully cast as one complex casting? Absolutely! But just because something can be cast does not always mean it should be. So, if you find yourself really struggling with a casting design, you may save yourself time and money talking with an experienced prototyper who can offer his counsel to help you achieve not only the best part design but also the most cost-efficient method of casting it.