Q.  How much does it cost?


The price is dependent upon the number of cooling lines, which roughly correlates to the size of the die.  The Die Therm Control System is not inexpensive.  However, because of the current lack of control over the thermal aspect of the process, and because most process variation is thermal in nature, payback periods (and inversely ROI) provide very compelling costs justifications.  Payback periods are typically less than 6 months.  Such paybacks are achieved, because thermal control results in benefits to multiple facets of the die casting process. 


Q.  This sounds complicated.  Will I be able to understand, implement, and use the Die Therm System?


The math and science that underlie the system are complex.  However, all of this is embedded in the software.  The Die Therm System does all of the calculations automatically, one of the key benefits of the system.


The proprietary software is PC-based, so the interface has the same look and feel of other standard, off-the-shelf PC-based software.


As part of the installation and implementation process, Die Therm provides on-site training to ensure that the Die Therm System can be effectively understood and operated by on-site personnel.


This is not say that this is a “magic box.”  As with anything new, there is a learning curve.  (However, as anecdotal evidence, everything on this site was written by an accountant who had zero die casting knowledge or experience in 2007.)



Q.  What about hot oil?


The Die Therm Control System is not designed to be used with hot oil.  However, the Die Therm Control System renders the use of hot oil obsolete.  Die Therm has proven that hot oil is not effective in preheating dies.  Hot oil has only a fraction of the heat removal capabilities of water.  So, during production it will have the effect of some passive cooling, but water is far superior.



Q.  We already use simulation software.  Isn’t that enough?


Simulation software is an excellent planning tool, but it provides no process control.  Use of the Die Therm Control System can actually improve simulations.  First, the design module of the software provides a good starting point from which to run simulations.  This greatly reduces the number of simulations required.


Second, the Die Therm Control System provides real-time data, which can be compared what simulations predicted.  Currently, there is no other way to compare expected data results from simulations to actual production results.



Q.  How much retrofitting of our equipment is required?


Generally, very little, if any.  The Die Therm System is designed as a “black box,” meter-out solution.  Minor modifications to cooling line connections may be required.  However, these are usually minor.



Q.  Maintenance.  Is this just something else that can break down that will require attention from maintenance?


The physical layout of the Die Them System was designed by a former die cast maintenance manager.  So, it is designed to be maintenance friendly.  As a current Die Therm customer has stated, “It just runs.”  Some regular maintenance is required.  However, any such maintenance should be more than offset by the reduction or elimination of unplanned down-time events.