Hybrid production, which combines die casting processes with subsequent precision machining, has become an essential solution for industries that demand high-performance components, tight tolerances and complex designs. This approach, increasingly common in sectors such as automotive, aerospace and electronics, allows you to leverage the strengths of both methods to obtain parts that meet the highest standards of quality and functionality.

In this article, we explore why this methodology is key for demanding projects and how Gestión de Compras helps our clients successfully implement hybrid solutions.

Why combine die casting and machining?

Die Casting

This process is ideal for manufacturing parts with complex geometries and high precision in large volumes. It uses a molten alloy that is injected at high pressure into steel molds, which guarantees:

• High initial precision: Ideal for parts that require complex shapes from the start.
• Reduction of excess material: Casting eliminates the need to machine large portions of material.
• Production speed: Can produce tens of thousands of parts per month, making it perfect for large series.

Machining

This process allows working on critical details, such as surface finishes, drilling, threading or tolerance adjustments. Its complementary function to casting includes:

• Ensuring smooth, polished surfaces where necessary.
• Achieving extremely tight tolerances, such as ±0.01 mm, that casting alone cannot achieve.
• Ensuring the functionality of parts in critical applications.

Technical benefits of hybrid production

• Material optimization: The combined use of both processes reduces material waste, especially in large or complex parts. For example, casting forms the overall base of the part while machining focuses only on areas requiring precise fits.
• Tight tolerances: Parts manufactured with this approach achieve very tight tolerances, necessary for critical components such as transmission cases in automobiles or aircraft internal structures.
• Material versatility: This method is compatible with a wide range of materials:
  • Light alloys: Such as aluminum and magnesium, perfect for weight reduction.
  • Denser metals: Such as steel, brass and copper, for parts requiring higher mechanical strength.
• Cost and time reduction: By integrating both processes into an efficient production chain, unnecessary steps are eliminated and lead times are shortened, which in turn reduces total project costs.

Highlighted use cases

• Automotive: Production of engine blocks and transmission cases, which require high precision in internal cavities and structural strength.
• Aeronautics: Production of lightweight structural components with complex internal cavities, such as brackets or aircraft housings.
• Electronics: Manufacture of housings for electronic devices, where specific finishes are needed to dissipate heat and ensure optimum performance.

How we do it in Gestión de Compras

In Gestión de Compras, we integrate both processes in the same production chain. This allows us to:

• Reduce production times: Minimize transfers between different facilities by consolidating processes.
• Guarantee consistency and quality: Constant monitoring during each stage to meet customer specifications.
• Customize each project: We tailor methods, tools and materials to the specific needs of each customer.

Our approach combines more than 20 years of industrial sourcing experience with advanced technology, ensuring that every project is a success. Interested in hybrid solutions for your company? Contact us to find out how we can optimize your manufacturing processes.