For release agent

• Very low mixing ratio 1:1 - 1:10, or purely oil-based release agents
• Very small quantities possible by so-called volumetric spraying (pulsed)
• Problems with over-spraying can be solved by micro-spraying
• Can be dosed exactly, only as much as necessary by as little as possible ("Less is more, even less is better")

In the process

• Reduction of cycle time → less spraying, no blowing out of residual release agents
• Reduction of compressed air
• Reduction of water
• Reduction of overspray
• Reduction of electrical energy for reheating the mold
• Reduction of release agent consumption
• Reduction of noise
• Small distance to the mould surface allows to reduce the pressure level
• Working with higher temperatures allows to optimize other parameters
• Increased efficiency of die casting process Resource-saving technology with high process reliability

For the mould

• No thermal shock on the mould surface
• No corrosion
• Increase in mould life

For the part quality

• Less porosity
• Less release agent deposition on the part surface, thus lower costs for further processing of the parts e.g. bonding, welding, KTL,...
• Lower rejection rate and better part quality

This results in significant potential savings:

• Energy costs: - 60-80%
• Compressed air: - 70-80
• Cycle time: - 10-20%
• Fresh water: - 99-100%
• Waste water: - 100%
• Mould life: + 50-300%

Optimized die cooling

• Surface temperatures should stay within 180° - 400°C
• Die has maybe to be modified to run at a higher temperature level
• A die that has sufficent cooling during production can be too cold at startup, therefore heating possibilities are also necessary

Collaboration

• Microspraying is a technologically demanding process, so close cooperation between the die casters and the suppliers is necessary before and during the start of the project