How Die Casting Defects Happen (And How We Minimize Them)

Even with precision equipment and trained operators, die casting defects can occur—often from subtle issues in mold design, material behavior, or process control. Knowing the most common types of casting defects helps both designers and buyers spot risks early and plan for prevention.

Common Defects in High-Pressure Die Casting:

1. Porosity

   Small voids or air pockets caused by gas entrapment or shrinkage. Porosity weakens the part and causes leaks under pressure.

   Prevention: Controlled fill speed, proper venting, and optimized runner design.

2. Cold Shut

   Two metal fronts fail to fuse, leaving a visible line or weakness.

   Prevention: Correct gate placement, metal temperature control, and injection profile tuning.

3. Flash

   Excess material leaks out of the parting line or ejector pin gaps.

   Prevention: Adequate clamping force, proper die maintenance, and tool alignment.

4. Misrun / Short Fill

   The cavity doesn’t fill completely.

   Prevention: Higher injection pressure, smoother flow paths, and proper die temperature.

5. Sink Marks / Shrinkage

   Surface depressions due to uneven wall thickness or localized hot spots.

   Prevention: Uniform wall design, proper cooling layout, and balanced solidification.

At LVIO Precision, we use first-shot analysis and real-time process monitoring to reduce defects from the start. We also provide DFM input before tooling kicks off—helping customers design castable parts that reduce risk of porosity, warping, or short-fill during production.