Metal Die Casting – Die Stamping are completely different manufacturing processes used for making metal badges. For die casting you can use bullion casting grain or recycled metal, while die stamping needs flat sheets of metal, to cast a badge the metal has to be heated beyond its melting point, while the metal stamping process doesn’t require any heat.
Die-casting tends to be utilized when a product has intricate complex details, bevelled edges or is 3D in form. Metal stamping works best for simple flat 2D designs. Stamping can be used to produce highly detailed items, however the more complex a design is the more the tooling costs will be.
Ferrous and non-ferrous metals are suitable for stamping, while only non-ferrous metals are best suited to die-casting. One main disadvantage of metal stamping is that you end up with quite a lot of scrap metal, however you can recycle this when you come to do a die casting badge job by re-melting the metal. View more metal badge manufacturing proceses.
PROS of Die stamping
1.The steel stamping tool lasts longer than a rubber mould, something to consider if you need thousands of products regularly.
2.The stamping process is far quicker than casting once the tool has been made, enabling less man hours and resulting in faster lead times.
3.You can use pre polished sheets of metal to save time prepping the surface fully
CONS of Die stamping
1.The tooling for die stamps costs more than a rubber mould used for die casting does.
2.You waste more metal with stamping large sheets, you also pay for the whole metal sheet needed to make a job even though the wastage isn’t directly used. Die casting only has tiny bits of scrap like sprues left over from the wax casting tree or mould so works out to be more cost effective. A sprue is formed by either creating a channel in a rubber mould through which the molten metal can flow through into the mould, once the metal has cooled down the sprue is created. The other way sprues are created is by attaching wax rods to wax models of jewellery which are then all assembled onto a tree like form ready to be lost wax cast, this method of casting requires a plaster cast of the wax tree which is then burnt out, the mould is now ready for pouring in molten metal then the plaster is broken off to reveal the metal cast tree.
3.Die cast badges take longer to finish, badges have to be put into a pin machine to de bur any rough edges after casting and to brighten/clean the metal before being sanded, polished then plated.
Overall the we feel labour time out ways material costs so Die stamping gets our vote in terms of profitability, however die casting is more versatile and is still very much needed within the industry.
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