Leveraging Statistical Analysis Software in Advancing Material Efficiency with Pore Die Casting

The Pore Die Casting Process 

Pore die casting introduces controlled porosity into components, effectively reducing aluminum usage without compromising the overall quality or functionality of cast parts. By managing porosity distribution strategically, this process achieves material efficiency and weight reduction, especially suited for components with lower stability requirements.

Final Thoughts on Pore Die Casting and Statistical Optimization

This exploration into pore die casting highlights how material savings and quality control can go hand in hand when process parameters are optimized systematically. The use of statistical methods—particularly through camLine’s Cornerstone software—proved essential in identifying and fine-tuning factors such as piston speed and press residue, which directly impact porosity, surface quality, and component weight.

The findings illustrate that structured data analysis—enabled by Cornerstone’s statistical functions—can bring clarity to complex relationships between casting parameters and product quality. In this case, the implementation of D-optimal experimental design with Cornerstone successfully optimizes the housing of a fuel cell stack. This approach is also adaptable to other molding processes—such as plastic and battery molding—for manufacturing optimization beyond just pore die casting.

For those interested in a deeper dive into the methodology, results, and broader implications, the full whitepaper is available on the Casting Plant & Technology website.

Citation: Jörg Hohlfeld, Christian Hannemann, Frank Schneider, Christian Fritsch, Andy Günther, Holger Petschel, Theo Wember, René Schmiedel. 2025. "Pore-die-casting – a way to save aluminum?" Casting Plant & Technology, 01/2025, 41–49.