Die Casting Process during Badges Manufacturing
Die casting is an alternative process of stamping and is used for large-size badges with complex designs, especially when there are holes in the badge design; for example, casting is done to imprint the person's face on the metal. Molten metal is shaped into a badge with high pressure. Here are the steps to
Die-cast a badge:
A mould is prepared with a metal sheet. The mould has two parts that fit together. An elaborate and detailed design is created inside the mould, where metal is then placed for die casting. Before casting, a special coating is applied inside the mould to prevent the badge from sticking to it.
Metal is heated to turn it into liquid form. The liquid metal is moved to a holding chamber to purify it for perfect badge finishing.
Molten metal is transferred to the mould to create a design using a high-pressure machine. Pressure and temperature are monitored to avoid bubbles in the fill. The mould is instantly transferred to a cold chemical for solidification.
The badge is taken out of the mould, and the extra metal is trimmed to give it a clean look.
Workers trim and cut the sharp edges. The badge is then polished in a machine to give it a shiny finish. It is then plated with gold, silver, or nickel, as per demand.
Die casting is a cost-effective method of badge manufacturing where the design and image are created in just one step. Workers handle each step in die casting to create high-quality badges.
