Are you looking for innovative die-casting solutions for the precise implementation of your individual requirements? Then Protocast is the right partner for you!
In close cooperation with our partners, we successfully complete numerous projects every day, and implement application-specific die-cast parts for our customers. We use the proven materials aluminium, zinc and magnesium for the production of castings. These offer various advantages in different applications. Our customers can therefore rely on a wide range of high-quality cast products for almost any application.
Your needs are our mission. With our first-class die-cast parts, we supply tailor-made solutions for a large number of companies in a wide range of industries – and we would be happy to do the same for your company.
What are you waiting for? Contact us – we look forward to working with you to develop the best solution for your application.
Highest level of quality, competence and speed through in-house production.
Deliveries within 72 hours possible thanks to sophisticated logistics and goods supply.
No manufactured component leaves our premises without strict quality control.
As your partner, we are personally available at any time to answer all your questions.
As a die-casting company with many years of experience, we combine tradition with innovation.
Close consultation with experienced experts to continuously reduce production costs.
We produce castings of various shapes: Here you can gain insight into our process for the production of first-class die cast parts. From inquiry to shipment, customers can rely on fully digitized and optimized die-casting production. We continuously combine the highest quality with fast inquiry and order processing in all manufacturing processes.
Get your individual offer now!Each of our manufacturing processes begins with the pre-qualification of the incoming inquiry. If necessary, we will be pleased to support you in further optimizing your production requirements.
Once your offer has been received and pre-qualification has taken place, you can usually expect to receive a quotation within 48 hours of receiving the request.
All incoming orders are processed fully automatically, whereby we ensure proactive communication of production and delivery dates at all times through digitalised processes.
Subsequently, all manufactured components are thoroughly tested according to ISO9001, and a test protocol is enclosed with the shipment.
Finally, we guarantee the uncomplicated receipt of your products through insured shipping in secure packaging, with transparent monitoring at the same time.
Die casting is a highly economical casting process for series or mass production, in which molten metal is pressed into steel moulds using industrial robots. These moulds are made of steel and are specially designed for each project. This allows components to be manufactured with precision and repeatedly.
Die casting is a fully automated process. Different casting alloys (such as aluminium, zinc or magnesium) with a low melting point are preferred.
We carry out the die-casting process internally. For this purpose we use high-quality casting machines and equipment.
In die casting, molten metal is poured into a steel mould and pressed – pressed!
In order to guarantee our customers the high, consistent quality of our cast products, the casting moulds (tools for die casting) are specially developed for each project on the basis of individual customer ideas.
A special feature of die-casting processes is the cost saving that is made possible by reducing further finishing steps. Products manufactured by the die-casting process are characterized by narrow tolerance ranges, as well as a high degree of consistency and dimensional accuracy of all components.
In die casting processes, a distinction can be made between two different types of die casting machines: The cold chamber and hot chamber process!
As the name already indicates, the two designs differ particularly in the feeding system, which makes the liquid metal melt available for the actual casting process.
The die casting alloys we offer are fully recyclable and thus make an important contribution to the long-term preservation of our environment. We also strive to carry out our work as efficiently and resource-sparingly as possible.
In order to remain a long-term supplier of innovative die-casting solutions for our customers, we also carry out continuous analyses of our die-casting systems so that their efficiency and precision can be sustainably optimised.
Holistic die-casting solutions: From planning to assembly
We offer our customers numerous, integrated solutions for every die-casting requirement.
In doing so, we only produce high-quality die-cast parts that have a high level of technical cleanliness.
It is also possible to extend the mechanical properties of the die-cast parts – by adding alloys – by adding mechanical properties. All our die-cast products can thus be optimally adapted to the customer’s application and thus enable safe application.
We can also carry out a surface treatment, by which the product can be provided with the surface properties you require.
In addition, we are your contact for all consulting questions regarding die-casting and will be happy to advise you on the selection of a suitable die-casting solution.
About the cold chamber process
In the cold chamber process, the die-casting machine and furnace are arranged separately. This makes it possible to dose the required amount of melt both manually and automatically.
For this purpose, we use modern machines that achieve optimum results with maximum economic efficiency for the customer.
The cold-chamber process is particularly suitable for aluminium- or copper-based alloys – it is almost indispensable in order to process even aggressive aluminium alloys without any problems.
However, it is also possible to produce zinc alloys using the cold chamber process.
Sequence of the cold chamber process
For each melting cycle, the required amount of melt is added to the casting chamber. There it is pressed by a movable casting piston into the intended casting mould at high speed.
The liquid metal finally solidifies under high pressure. The actual production of the workpiece is now complete.
In addition, the surplus, which consists of castings, overflows and press remnants, is ejected after opening the die-casting mould and deposited by the removal device.
Compared to the cold chamber process, the hot chamber process offers a decisive special feature. For example, the melt, whose temperature is kept constant in a crucible, has a design that ensures a connection from furnace to mould.
In the technical language this device is also called a pouring vessel. In the hot chamber process, the holding furnace and the die-casting machine form a single unit.
In the furnace itself, temperatures of approx. 450 degrees Celsius prevail in the die-casting process.
As a result, our customers can rely on fine-grained castings that also have low heat dissipation.
Furthermore, the metal flowing into the casting chamber does not come into contact with air, so that oxidation and air inclusions can be completely avoided.
However, no materials containing aluminium or copper can be used using the hot chamber process. These would dissolve the material of the casting chamber.
Sequence of the hot chamber process
By means of hot chamber processes – and possibilities of automation – cast products can be produced in short cycle times.
Depending on the size of the machine, workpieces can be cast within three to four seconds.
In the hot chamber process, the casting vessel is permanently in the liquid melt of the crucible. Here the plunger moves downwards at the beginning of the cycle and thus transports liquid metal into the cavities provided in the mould. Finally, liquid metal enters the casting chamber by moving the plunger upwards at the end of the cycle.
In the die casting process, alloys are pressed into a (steel) mould under high pressure.
Zinc, aluminium and magnesium are the most commonly used die-casting alloys:
Thus the later workpieces – depending on the alloy used – have different mechanical properties – and can thus be optimally adapted to the specific requirements of a wide range of applications.
This enables us to produce high-quality cast products for our customers for almost any application.
Moreover, die casting alloys not only withstand high operating temperatures, but also have excellent ecological compatibility – they are therefore completely recyclable.
We only offer die casting alloys with:
on!
In die-casting, complicated geometries can be realized for use in different areas of application. It is therefore hardly surprising that die-cast products are used reliably in almost all areas of application.
In particular, the wide range of different alloys available allows application-specific adaptations of the cast products.
It is best to look directly at the respective casting process to obtain further information on application areas.
Otherwise, we are of course available to you at any time as your contact partner. Here you can fully rely on the advice of experienced engineers, who always know exactly which die casting process is advantageous in the respective area of application.
We also have an in-house toolmaking department. This is the linchpin in the creation of new castings.
In order to ensure the high quality of the castings, we work here with the highest precision and the most modern machines using a wealth of experience.
A great advantage of the alloyed tool steels is that they guarantee the output of maximum quantities from the die-casting moulds.
We also manufacture devices for deburring the castings as well as for mechanical processing in our internal toolmaking department.
With our innovative processes for casting production, we can meet even the most complicated customer requirements time and again.
Whether manufactured die-cast parts made of aluminium, zinc or magnesium:
there are numerous advantages for customers to fall back on the high-quality die-casting solutions from PROTOCAST.
Die-cast products offer the customer smooth and clean surfaces and edges. Thus, very precise products are manufactured which can be optimally integrated into the customer’s specific application.
The die-casting process also allows products with thinner walls and narrower tolerance ranges to be realized than with other processes.
The die casting process is also a good choice as it saves resources and thus contributes to long-term cost reduction, in addition to protecting the environment. Thus, the die casting process results in exact, precise products that make further steps of finishing superfluous.
A further advantage of our die-cast products is that the mechanical properties of the cast products can be easily extended by different alloys, which ensures safety in use even in critical (demanding) applications.
