Die Casting Design Guidelines

• Wall Thickness — Keep uniform, 1.5–4mm for aluminum, 1–3mm for zinc
• Draft Angles — 1–2° for external walls, 1.5–3° for internal, 3–5° for deep cavities
• Fillets — Minimum R0.5mm, R1–2mm preferred to reduce stress concentration
• Ribs — Use ribs for stiffness, base thickness 0.6–0.8× wall thickness
• Undercuts — Use slides/corings, avoid complex multi-slide designs