How to Minimise Warpage in CNC-Machined Castings

One of the biggest headaches in machining die-cast parts is warpage — where the part distorts after casting or during machining, throwing tolerances out of spec.

🔍 Why does warpage happen?

• Residual stress from the casting process (uneven cooling or alloy segregation)

• Thin walls or asymmetrical designs that don’t distribute stress evenly

• Aggressive machining cuts that release internal stress suddenly

• Improper clamping or fixturing during machining

  
  

⚙ How to minimise it:

✅ Design for uniform wall thickness

✅ Include machining stock where necessary for stability

✅ Use balanced machining operations (cut evenly from both sides)

✅ Apply stress-relief heat treatment before machining (where applicable)

✅ Use well-designed fixtures that support the part properly

👨‍🏭 LVIO Precision’s value-add:

We spend alot of time discussing design and tolerances with our customers, to anticipate warpage risks early. This includes reviewing casting design, specifying heat treatments if needed, and developing machining strategies that keep parts true. Our in-house CMM ensures that final dimensions meet spec — no surprises at assembly.