Die Casting Four-Plate Mold Technology Saves Up to 20 Percent in Weight

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Krämer & Grebe GmbH & Co. KG

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Taiwan Machine Tool & Accessory Builders' Association (TMBA)

SIMTOS (Seoul International Machine Tool Show)

The toolmaking specialist Krämer + Grebe has developed the four-plate mold technology. This allows for multiple direct gating connections directly to functional component areas in aluminum die casting. This can save up to 20 percent weight while maintaining the same component function.

To produce aluminum cast products in premium quality, numerous factors must be optimally coordinated. These include the number and layout of gates, mold temperature control, part and gating system removal, spraying technology, as well as melt temperature and injection process. Increasingly complex geometries, high dimensional accuracy, and cost-efficient series production are in demand.

The four-plate mold technology opens up new possibilities: Through an additional parting plane in the tool structure, complex contours, undercuts, and slide movements can be realized. Especially for large structural components and automated processes, the four-plate design offers clear advantages over conventional tool concepts.

Tool Technology for Complex Components Now Ready for Series Production

The toolmaking specialist Krämer+Grebe from Biedenkopf has successfully implemented its four-plate tool technology on a 6,300 short tons die-casting machine. This has proven that this complex tool concept is not only technically feasible but also suitable for series production. Especially for demanding aluminum cast parts with thin wall thicknesses and function-optimized geometry, the technology offers entirely new possibilities—while simultaneously improving cost-efficiency and process reliability.

At the core is the development of a fourth tool plate, which not only enables additional parting planes and gating positions but also ensures controlled gating break-off during mold opening. This allows multiple direct gates to be connected immediately to functional component areas, instead of purely flow-optimized layouts. Wall thicknesses and flow paths are shortened, solidification can be controlled, and potential shrinkage porosity is avoided. In practice, this means: up to 20 percent weight reduction while maintaining component functionality, shorter cycle times, and lower material consumption.

Additionally, the proximity of the gates to the component allows for early separation, minimizing rework effort and increasing production speed. The die parting surface can be reduced since the gating system is located in the "shadow" of the component— an advantage particularly relevant for multi-cavity tools and giga-casting components.

Innovation in Detail: Cooling, Maintenance, Process Control

Krämer+Grebe has developed wear sleeves and 3D-printed cooling sleeves to meet the high demands of temperature control. These ensure targeted cooling of individual gating pipes—a crucial factor for consistent component quality. The system is complemented by a hydraulically controlled holding system that prevents uncontrolled shifting of the detached gating and ensures precise removal positioning.

Another highlight: The fourth plate features an integrated cleaning and maintenance function, allowing wear parts to be serviced or replaced directly on the machine—a crucial contribution to process reliability and system availability.

Future-Proof Platform for Series Production

With the new tool concept, Krämer+Grebe addresses the challenge of producing large components economically, reproducibly, and with consistently high quality. The mold is designed for maximum robustness, ease of maintenance, and durability. Especially in high-pressure die casting, where tools are subjected to enormous thermal and mechanical stresses, every component must be manufactured with repeatable precision.

The result: a scalable, forward-looking tool concept that makes existing die-casting machines more efficient—whether for large individual components or the parallel production of multiple components in a single shot. The four-plate technology saves material, time, and costs—paving the way for new product generations in aluminum die casting. The team at Krämer+Grebe proudly looks back on the moment of the first cast—accompanied by the "snap" of the successful break-off and a component that met all expectations.

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