,transcrib]'s ,note3 ,subscripts are    
prec$$ by an acute acc5t m>k 2  italic  
text is enclos$ 9 und]scores4           
,illu/ration            ,,ma*9]y',s     
,,ref]5ce ,,s]ies        ,,ea* ,,numb]  
,,is ,,"o ,,unit ,,9 ,a ,,complete      
,,libr>y ,,( ,,ma*9e ,,design    ,,&    
,,%op ,,practice ,,revis$ ,,&           
,,republi%$ ,,f ,,ma*9]y        ,,numb] 
#aji      ,,die ,,ca/+                  
,,dies--,,ma*9es--,,me?ods      ,by     
,,*e/] ,l4 ,,lucas          ,,cont5ts   
,die ,ca/+                              
#c        ,mak+ ,dies = ,die-,ca/+      
,ma*9es            #ae        ,van      
,wagn] ,mfg4 ,co4's ,die-,ca/+ ,practice
      #bg        ,copyright1 #aiac1 ,!  
,indu/rial ,press1 ,publi%]s ( ,,ma*9]y1
    #di-ee ,lafayette ,/reet1 ,new ,york
 ,city          ,,*apt] ,i    ,,die     
,,ca/+      ,die-ca/+1 a comp>atively   
rec5t me?od = produc+ f9i%$  ca/+s1 is  
rapidly prov+ itself an important factor
 9 !  economical manufacture (          
int]*angeable p>ts = add+ ma*9es1       

typewrit]s1 telephones1 automobiles &   
num]\s o!r products :]e  x is ess5tial t
 ! p>ts be nicely f9i%$ & accurate 9    
dim5sions4 ,! t]m 8die-ca/+0 is         
self-explanatory1 mean+ 8to  ca/ by     
means ( dies02 describ$ briefly1 !      
process consi/s (  =c+ molt5 metal into 
/eel dies1 all[+ x to cool 9 !m1 &  !n  
op5+ ! dies & remov+ ! f9i%$ ca/+4 ,x is
 !  purpose ( ?is treatise to give a    
g5]al outl9e ( ! die-ca/+  process1 %[+ 
its possibilities & limitations1 & also 
to give  a description ( ! die-ca/+     
ma*9]y & its op]ation1 (  ! fundam5tal  
pr9ciples involv$1 & ( ! me?ods us$ 9 ! 
die-mak+4 ,illu/rative examples ( ! be/ 
types ( dies1 bas$ on  results obta9$ f 
actual exp]i5ce1 w also be giv54        
,orig9 ( ,die ,ca/+    ,! orig9 ( !     
die-ca/+ process is some:at difficult to
  asc]ta94 ,we may look into ! hi/ory ( 
type f\nd+ & f9d  t away back 9 #ahch1 !
 fir/ ca/+ ma*9e = type1 inv5t$  by     
,bruce1 0 a ma*9e t involv$ ! pr9ciples 
( die-ca/+  z x is practic$ to-day4 ,m  

rec5tly1 9 #ahhe1 ,otto ,m]g5?al]       
br\ght out ! l9otype ma*9e4 ,?is ma*9e  
is a good example (  a die-ca/+ ma*9e4  
,h[ev]1 z we int]pret ! ^w to-day1      
die-ca/+ is a broad] t]m ?an type-ca/+  
or l9otyp+1 al?\gh  its developm5t )\t  
d\bt is due to ! success ( ! l9otype    
ma*9e4 ,x is d\btful if die-ca/+1       
prop]ly speak+1 0  orig9at$ until ab\t  
fifte5 ye>s ago1 & x is c]ta9 t x is    
only dur+ ! pa/ few ye>s t ! activities 
9 ?is l9e h  be5 v noticeable4    ,"o ( 
! fir/ exp]im5ts 9 ! direction (        
die-ca/+ 0  und]tak5 to get out "s rubb]
 mold p>ts *eaply en\gh to leave a      
pr(it on a job t 0 beg9n+ to look dubi\s
 f ! f9ancial  side4 ,! molds 7 = mak+  
rubb] plates ab\t ?ree in*es  squ>e &   
"o-eigh? in* ?ick1 ! top side ( :i* 0   
decorat$  ) f9e rais$ scroll "w2 x 0 ?is
 latt] feature t gave  ! tr\ble4 ,aft]  
wa/+ mu* "t & money try+ to /amp !  mold
 p>ts1 a metal-tight box 0 made z %[n 9 
,figs4 #a & #b )  a block screw$ 9 x1 ! 
purpose ( :i* 0 to %ape ! mold          

impression & imp>t to x ! scroll design4
 ,z %[n1 ! ends (  ! box 7 removable1   
be+ screw$ on4 ,?is box 0 plac$ "u  a   
screw press & a /raight plung] t j fill$
 ! top ( !  box 0 fitt$ to ! head ( !   
press4 ,aft] ! two 7 l9$ up1  molt5 type
 metal 0 p\r$ into ! box1 & z soon z !  
metal  _h cool$ to ! 8mu%y0 /ate1 ! ram 
( ! press 0 =c$ d[n  z %[n 9 ,fig4 #b4  
,next1 ! ends ( ! box 7 remov$1 ! screw 
hold+ ! block tak5 out1 & ! die-ca/+    
pu%$ f ! box4  ,! object 9 hav+ ! incl9$
 side to ! box 0 to produce a  piece    
%ap$ ) ! prop] incl9ation = its position
 9 ! f9al  mold us$ = ca/+ ! rubb]      
plates4 ,! illu/rations give an idea  ( 
! compression t took place4 ,! die-ca/+ 
0 f\nd to be  %>p at ! corn]s & free f  
flaws1 & ! scroll "w came up  9 f9e     
%ape4 ,naturally ! re/ ( ! mold p>ts 7  
made 9 !  same way & ! job turn$ f      
failure into success4    ,illu/ration3  
,fig4 #a4 ,an ,e>ly ,exp]im5t 9 ,die    
,ca/+--,be=e ,apply+ ,pressure          
,fig4 #b4 ,an ,e>ly ,exp]im5t 9 ,die    

,ca/+--,aft] ,apply+ ,pressure      ,f  
su* simple exp]im5ts z ^!1 ! die-ca/+   
indu/ry has  develop$ to its pres5t     
/age4 ,9 view ( ! advances t h be5  made
 9 die-ca/+1 x is s+ul> t !re are to-day
 only ab\t  a doz5 conc]ns 9 ! bus9ess 9
 ?is c\ntry1 b z ! subject  becomes     
bett] und]/ood1 & ! possibilities ( !   
process are  realiz$1 ! dem& = ?is class
 ( ca/+s w result 9 _m  o!r firms go+   
into ! "w1 & x is n improbable t a l>ge 
numb] ( factories w in/all die-ca/+     
plants ( _! own to aid  !m 9 produc+    
bett] "w 9 a m economical way4          
,advantages1 ,possibilities &           
,limitations ( ,die ,ca/+    ,! greate/ 
advantage ( die-ca/+ is ! fact t ! ca/+s
  produc$ are completely & accurately   
f9i%$ :5 tak5 f !  dies4 ,:5 we say     
completely1 we mean t absolutely no     
ma*9+ is  requir$ aft] ! piece has be5  
ca/1 z x is ready to slip into its      
place 9 ! ma*9e or device ( :i* x is to 
be a "p4 ,:5 we say  accurately1 we mean
 t ea* piece w come f ! die an exact    

c\nt]p>t ( ! la/ "o2 & if ! dies are    
c>efully made1 !  ca/+s w be accurate )9
 #j4jja in* on all dim5sions1 :e!r  !y  
are outside measurem5ts1 diamet]s (     
holes or radii4 ,all holes  are ca/ &   
come out smoo!r ?an !y c\ld be ream$2   
lugs & ge>  tee? are ca/ 9 place2       
?reads1 ext]nal & int]nal1 & ( any      
desir$ pit* c be ca/4 ,oil grooves c be 
ca/ 9 be>+s1 &1 9  a ^w1 any piece t c  
be ma*9$ c be die-ca/4    ,! sav+ 9     
ma*9+ works bo? ways2 n only is all     
ma*9e "w  elim9at$ by ! "o op]ation (   
ca/+1 b ! ma*9e tools &  ! workm5       
necess>y = _! op]ation & up-keep are    
disp5s$  )1 ! exp5se ( build+ jigs &    
fixtures is /opp$2 & no  cutt]s1 ream]s1
 taps or drills are requir$ = ?is bran* 
( !  production4 ,9 addition1 ! labor   
requir$ = op]at+ ! ca/+  ma*9es may be  
class$ z unskill$4 ,no matt] h[         
intricate &  exact+ ! ma*9e "w on a     
piece has be51 & h[ skillful a  workman 
0 requir$ to produce ! "w :5 ma*9e-made1
 ! same  result may be br\ght ab\t by   

die-ca/+1 & usually ! "w is  excell$1 &1
 exclud+ ! die-mak+1 unskill$ m5 c make 
!  p>ts4    ,f a metallurgical /&po9t a 
die-ca/+ is sup]ior to a  s&-ca/+ on    
acc\nt ( its d5sity1 /r5g? & fre$om f   
bl[-holes4 ,also1 :5 ! hot metal comes 9
 contact ) ! cool  dies1 x =ms a 8sk90  
simil> to ! scale on an iron s&-ca/+4   
,z ! die-ca/+ requires no ma*9+ aft]    
leav+ ! dies1 ?is  sk9 increases ! we>+ 
qualities ( ! ca/+4    ,! possibilities 
( die-ca/+ are num]\s4 ,by ?is me?od (  
manufactur+ x is possible & practical to
 ca/ pieces t c\ld  n possibly be ma*9$4
 ,x is an e-day occurr5ce to make  ca/+s
 ) ins]t$ p>ts ( ano!r metal1 z1 =      
in/ance1 a  z9c :eel ) a /eel hub4 ,x is
 also possible to make babbitt  be>+s t 
are h>d] & bett] ?an c be made 9 any o!r
 way4  ,(t5 !re are two or m p>ts ( a   
device t h =m]ly be5  made sep>ately1   
ma*9$ & assembl$1 t c be die-ca/ z "o   
piece4 ,9 su* cases ! sav+ 9 production 
is v great4 ,figures  & lett]s may be   
ca/ sunk5 or 9 relief on :eels = c\nt+  

or pr9t+1 & ( c\rse ornam5tation may be 
ca/ on pieces t  require ext]ior f9i%4  
,z to size1 !re is no def9ite limit to !
  "w t c be ca/4 ,"o job t is be+ done  
at ! pres5t "t  is a disk #af in*es 9   
diamet] ) a r\nd flange #a in* 9        
diamet]1  ar\nd ! rim4    ,illu/ration3 
,fig4 #c4 ,examples ( ,die-ca/+s        
8,!re is no great ga9 )\t "s small      
loss10 is j z true ( a  process l       
die-ca/+ z x is ( any?+ else4 ,!        
limitations (  ?is "w are few1 h[ev]1 & 
!y are "h giv5 s z to /ate !  situation 
fairly4 ,g5]ally speak+1 a "p %\ld n be 
consid]$  = die-ca/+ if !re are b few   
pieces requir$1 because ! co/  ( ! dies 
w\ld usually be prohibitive4 ,(t51      
h[ev]1 x happ5s  t because ( ! l>ge     
am\nt ( accurate ma*9e "w be+ done on  a
 ma*9e "p1 x is economical to make a die
 = ! comp>atively  small numb] ( p>ts   
requir$ & die-ca/ !m4 ,a case illu/rat+ 
?is phase ( ! matt] rec5tly occurr$ 9   
actual practice4 ,9  gett+ out an ord] (
 two hundr$ v5d+ ma*9es1 x 0 decid$  to 

try die-ca/+ on a "p t 0 difficult to   
ma*9e4 ,! dies  7 exp5sive1 co/+ #bjj1 &
 z !re 7 only #bjj pieces to be  ca/1 ! 
die co/ p] piece 0 "o doll>2 b ev5 ) t  
initial  h&icap1 x 0 f\nd t on acc\nt ( 
! difficult ma*9+ t  _h =m]ly be5       
requir$1 ! die-ca/ p>ts effect$ a l>ge  
sav+1  & ( c\rse ! results 7 sup]ior4   
,a r\gh "p t w\ld require little or no  
ma*9+ %\ld n  be die-ca/1 because p\nd =
 p\nd1 ! die-ca/+ metals co/  m ?an ca/ 
iron or /eel4 ,! ca/+ ma*9e _c make p>ts
  z rapidly or ( z h>d metals z ! pun*  
press or ! automatic  screw ma*9e4 ,=   
?is latt] reason a "p t necess>ily mu/  
be  made ( brass1 iron or /eel1 _c be   
die-ca/1 al?\gh mixtures  approximately 
equal 9 /r5g? to iron & brass are       
readily die-ca/4  ,to give add$ /r5g? to
 a die-ca/ "p x is (t5 advisable to  add
 webs & ribs or to ins]t brass or iron  
p9s at po9ts t are  weak or subject to  
h>d we>4 ,r\ghly speak+1 x is ! "p t    
has requir$ a good deal ( accurate ma*9e
 op]ations t %[s !  greate/ diff]5ce 9  

co/ :5 die-ca/1 & sometimes ! sav+ is  z
 great z #hj p] c5t4      ,! ,metals us$
 9 ,die ,ca/+    ,! metals t produce !  
be/ die-ca/+s are alloys ( lead1 t91    
z9c1 antimony1 alum9um & copp]1 & ! bulk
 ( ! die-ca/+s  made at ! pres5t "t are 
mixtures ( ! fir/ f\r ( ^!  metals4 ,f  
!m1 compositions may be made t w meet ! 
requirem5ts ( ne>ly any "p4    ,= p>ts t
 p]=m little or no actual "w1 save to   
8l5d  _! weight10 su* z balance weights1
 novelties & ornam5ts =  %[ w9d[s1 etc41
 a mixture consi/+ pr9cipally ( lead1   
(t5  /iff5$ ) a little antimony1 is us$4
 ,!re is b little /r5g?  to ?is metal1 b
 x is us$ because ( its weight & l[ co/4
  ,= p>ts t are subject to we>1 su* z   
phonograph1 telephone1  gas-met] & add+ 
ma*9e p>ts1 an alloy compos$ ( z9c1 t9 &
  a small am\nt ( copp] is us$4 ,?is    
alloy may be plat$ or japann$1  & is a  
good metal to use on g5]al "w4    ,ano!r
 metal1 us$ *iefly = ca/+ pieces t h    
delicate  po9ts 9 _! design b are n     
subject$ to h>d we>1 consi/s  pr9cipally

 ( t9 alloy$ ) lead & z9c to suit !     
requirem5ts  ( ! "w4 ,?is mixture ca/s  
freely1 & ! f9i%$ ca/+s come  out       
exceptionally clean4 ,/ill ano!r metal1 
us$ *iefly = ca/+  pieces t h lett]s &  
figures = pr9t+1 is simil> to !  /&>d   
type metal--#e p>ts lead & #a "p        
antimony2 b if !re are  tee? ca/ on !   
sides ( ! pr9t+ :eel a h>d] mixture w be
  requir$ to give long] life to ! ge>s4 
,! foll[+ mixtures are typical (        
die-ca/+ or 8:ite brass0  alloys3 copp]1
 #aj p>ts2 z9c1 #hc p>ts2 alum9um1 #b   
p>ts2 t91 #e  p>ts4 ,ano!r is copp]1 #f 
p>ts2 z9c1 #ij p>ts2 alum9um1 #c p>ts2  
t91 #a "p4 ,ano!r conta9+ antimony is   
copp]1 #e p>ts2 z9c1 #he  p>ts2 t91 #e  
p>ts2 antimony1 #e p>ts4 ,%onb]g's      
pat5t$ alloy is  copp]1 #c p>ts2 z9c1   
#hg p>ts2 t91 #aj p>ts4 ,alloys conta9+ 
#ae to  #dj p] c5t copp] & #fj to #he p]
 c5t z9c are brittle1 hav+ l[  /r5g? &  
l[ ductility4 ,an alloy ( #h p] c5t     
copp]1 #ib p] c5t  z9c has great]       
resili5ce & /r5g? b n ! ductility ( ca/ 

z9c4    ,alum9um may be ca/1 b x is a   
difficult metal to run into ?9  walls & 
f9e details2 x plays1 h[ev]1 an         
important "p 9 "s  good mixtures us$ =  
die ca/+4 ,exp]im5ts are n[ be+ conduct$
  = die-ca/+ manganese bronze1 & x is   
said t "s v good  ca/+s h already be5   
made4 ,its we>+ qualities are s valuable
  t x is p>ticul>ly desirable = mak+    
die-ca/+s4      ,! ,die-ca/+ ,ma*9e     
,! ?ree important requisites = good     
die-ca/+ are ! ma*9e1  ! dies & ! metal4
 ,! ca/+ ma*9e is fully z ess5tial z    
ei!r ( ! o!r requisites1 & al?\gh !re   
are a numb] (  diff]5t /yles ( ca/+     
ma*9es 9 use1 ea* ( :i* has its         
advantages ov] ! o!rs1 especially 9 !   
eyes ( _! respective  design]s1 !       
fundam5tal pr9ciples ^u :i* !y all      
op]ate are  ! same4 ,9 ea* !re is !     
melt+ pot & ! burn]1 ! cyl9d]  & ! pi/on
 = =c+ ! metal into ! dies1 & ! dies )  
! op5+ & clos+ device4 ,9 "s ma*9es     
pressure is appli$ to  ! metal by h&1 9 
o!rs p[] is us$1 & 9 /ill ano!r class  !

 metal is =c$ into ! dies ) compress$   
air4 ,! provisions  = op5+ & clos+ !    
dies v>y 9 ! diff]5t ma*9es2 !re  are   
v>i\s means employ$ = cutt+ ! sprue1 & !
 /yles (  heat]s are num]\s4    ,"o or  
two ( ! l>ge/ firms 9 ! die-ca/+ indu/ry
 h  automatic ca/+ ma*9es = turn+ out   
duplicate "w 9 l>ge  quantities v       
rapidly4 ,^! ma*9es are complicat$ & are
 only  pr(itable on l>ge quantities (   
"w1 & = t reason _!  use is n ext5sive4 
,9 g5]al1 _! op]at+ pr9ciples are !     
same z 9 ! case ( ! h& ma*9es1 b        
provision is made =  automatically op5+ 
& clos+ ! dies1 compress+ ! metal1 &    
eject+ ! ca/+s4      ,! ,soss ,die-ca/+ 
,ma*9e    ,! ,soss die-ca/+ ma*9e1      
manufactur$ & sold by ! ,soss           
,manufactur+ ,co41 ,brooklyn1 ,n4 ,y41 0
 ! fir/ die-ca/+ ma*9e  to be plac$ on !
 op5 m>ket4 ,?is ma*9e is %[n 9 ,figs4  
#d &  #e1 & 9 section 9 ,fig4 #f4 ,!    
,soss ,manufactur+ ,co4 orig9ally       
manufactur$ invisible h+es exclusively4 
,at ! adv5t ( !  die-ca/+ era1 !y       

comm5c$ to make ^! h+es f die-ca/+s1  & 
plac$ ord]s ) a lead+ die-ca/+ conc]n   
am\nt+ to  ?\s&s ( doll>s ea* ye>4 ,aft]
 ! die-ca/ h+es _h be5 on  ! m>ket = a  
%ort "t1 compla9ts comm5c$ to come 91 "s
 to  ! effect t ! h+es 7 break+ & o!rs t
 ! h+es  7 corrod+4 ,ei!r ( ^! faults 0 
s]i\s en\gh to bla/ !  reputation ( !   
h+e1 b ! fir/ tr\ble1 breakage1 0 ! m   
important4 ,exam9ation ( ! brok5 h+es   
%[$ t ! ca/+s  7 por\s & full ( flaws1 &
 z ! mak]s ( ! ca/+s  c\ld n produce    
ca/+s suffici5tly /rong = ! h+es1 ,mr4  
,soss />t$ to exp]im5t = himself4 ,?is  
exp]im5t+ l$ to !  production ( ! ,soss 
die-ca/+ ma*9e4    ,illu/ration3 ,fig4  
#d4 ,g5]al ,view ( ! ,soss ,die-ca/+    
,ma*9e    ,ref]r+ to ! illu/rations     
,figs4 #e & #f1 ,a is ! base & frame  ( 
! ma*9e1 ,b is ! heat+ *amb] locat$ at  
"o end ( !  ma*9e1 & )9 ?is heat+ *amb] 
is ! tank ,c1 %[n 9 ,fig4  #f4 ,?is tank
 conta9s ! metal f :i* ! die-ca/+s are  
made1  & ! metal is heat$ by ! burn]s   
,d4 ,^! burn]s are f$ by  air & gas     

?r\gh pip+ on ! side ( & b5ea? !        
furnace4 ,to  facilitate light+ ! burn]s
 & inspect+ _! condition at any  "t1 !re
 is an op5+ 7n %[n7 ?r\gh ! firebrick   
l9+ (  ! furnace & ! out] iron wall1 on 
a level ) ! top ( !  burn]s4 ,!re is    
also ano!r op5+ ?r\gh ! furnace wall to 
all[ ! gases due to ! combu/ion to      
escape4 ,?r\gh ! bottom (  ! tank1 well 
to ! inn] side ( ! furnace1 runs !      
cyl9d] ,e4  ,bel[ ! bottom ( ! tank1 !  
cyl9d] makes a "r-angle turn1  ext5d+   
?r\gh ! furnace wall & t]m9at+ j outside
 ( !  wall4 ,! orifice ( ?is cyl9d] is  
controll$ by gate ,f4 ,9 t  "p ( !      
cyl9d] t ext5ds upw>d into ! tank1 !re  
is an  op5+ ,g t all[s ! molt5 metal to 
run into ! cyl9d] f  ! tank4 ,work+ 9   
?is cyl9d]1 is ! pi/on ,h1 t is us$ 9   
=c+ ! metal into ! dies4 ,! compression 
lev] ,i1 h+$ ov]  ! inn] furnace wall1  
is kept normally rais$ by spr+ pressure1
 &  is connect$ to ! pi/on by means ( ! 
l9k ,j4    ,illu/ration3 ,fig4 #e4      
,work+ ,p>ts ( ! ,soss ,die-ca/+ ,ma*9e 

,at ! opposite end ( ! ma*9e f !        
furnace1 is ! me*anism  = op]at+ ! dies4
 ,?is me*anism consi/s ( a pair ( squ>e 
rods ,k1 ^u :i* are m\nt$ ! sleeves ,l4 
,^! sleeves h  a long be>+ surface & are
 atta*$ to ! die-plate ,m4 ,lev]  ,n at 
! end ( ! op]at+ me*anism controls !    
movem5t (  ^! sleeves by means ( l9ks   
,o4 ,^u ^! sleeves is m\nt$ a  second>y 
set ( sleeves ,p1 atta*$ to ! o!r       
die-plate ,q1  & ^: movem5t is controll$
 by lev] ,r1 ?r\gh l9ks ,s4  ,?is second
 set ( sleeves is free to travel ) !    
fir/ set1 &  9 addition has an indep5d5t
 movem5t ( its own on ! prim>y  sleeves4
 ,x is ! function ( lev] ,r to br+      
die-plate ,q up  to die-plate ,m by     
means ( l9ks ,s & sleeves ,p2 & x is  ! 
function ( lev] ,n to br+ bo? ( !       
die-plates up to !  outlet ( ! cyl9d] by
 means ( l9ks ,o & sleeves ,l4 ,?is     
sy/em ( sleeve-m\nt+ is "o ( ! di/9ctive
 pat5t$ features  ( ! ,soss ma*9e4 ,!   
orifice ( ! cyl9d] ,e is conical 9  %ape
 & exactly fits ! cup-%ap$ op5+ 9       

die-plate ,m1 s  t :5 ! two are br\ght  
toge!r1 ! jo9t is metal tight4 ,at  !   
c5t] ( ?is op5+1 & ext5d+ ?r\gh !       
die-plate ,m1  is an op5+ t leads to !  
dies m\nt$ on ! inn] faces ( !  two     
die-plates1 & a cont9uation ( ?is op5+  
ext5ds ?r\gh  die-plate ,q 9 :i* !      
sprue-cutt] ,u works4 ,atta*$ to !  out]
 side ( ?is die-plate are two slott$    
brackets4 ,9 ! slot (  "o ( ^! is pivot$
 ! lev] ,t1 & 9 ! slot 9 ! opposite     
bracket are bolt$ two /ops t limit !    
motion ( ! lev]4 ,?is  lev] op]ates !   
sprue cutt] ,u1 t works ?r\gh ! op5+ 9  
die-plate ,q4 ,! sprue-cutt+ me*anism is
 be/ %[n 9 ,figs4 #e &  #f4 ,at ! left (
 ,fig4 #e may be se5 a rubb] hose       
connect$ to ! air  pip+4 ,?is hose is   
us$ = clean+ out ! dies aft] ea* ca/+   
op]ation4      ,op]ation ( ! ,die-ca/+  
,ma*9e    ,! metal = ! die-ca/+ ma*9e is
 mix$ 9 ! prop]  proportions = ! "w 9 h&
 by means ( a sep>ate furnace1 be=e  be+
 p\r$ into ! tank ( ! ma*9e itself4 ,!  
burn]s are  light$ & ! dies are set up  

on ! two die-plates4 ,z soon z !  ma*9e 
has 8w>m$ up10 s t ! metal is 9 a       
?or\ghly melt$  condition1 ! sprue-cutt+
 lev] ,t is ?r[n back1 leav+ a cle>     
passageway to ! die cavities4 ,lev] ,r  
is pull$ backw>d1 ?us  br++ die-plate ,q
 up to die-plate ,m1 :i* op]ation closes
  ! two halves ( ! die4 ,!n lev] ,n is  
?r[n =w>d1 !reby  br++ ! clos$ die up to
 ! body ( ! ma*9e1 ) ! nozzle  9 close  
contact ) ! outlet ( ! cyl9d]4 ,next1 ! 
gate ,f  is op5$1 & ! man at !          
compression lev] ,i gives ! lev] a      
quick1 h>d pull1 =c+ ! metal 9 ! cyl9d] 
d[nw>d & into  ! dies4 ,! molt5 metal   
lit]ally 8squirts0 into ! dies4 ,gate ,f
  is n[ clos$2 lev] ,n is pull$ back to 
remove ! dies f !  cyl9d] outlet2 & !   
sprue-cutt+ lev] ,t is pu%$ =w>d1  cutt+
 (f ! sprue & pu%+ x out ( ! nozzle into
 ! kettle  plac$ b5ea? x4 ,! lev] ,r is 
pu%$ =w>d1 & a f9i%$  ca/+ is eject$ f !
 dies4    ,an important advantage t ?is 
ma*9e has ov] o!r die-ca/+  ma*9es is ! 
fact t ! metal = ! ca/+s is tak5 f !    

bottom ( ! melt+ pot1 :]eas mo/ o!r     
ma*9es use metal f  ! top ( ! tank4 ,at 
! bottom ( ! tank ! metal is always !   
be/1 z x is free f impurities & dross2  
h5ce1 !re is little  *ance = ! =mation (
 bl[-holes4 ,a h&ful ( ros9 ?r[n  into !
 melt+ tank occasionally helps to keep !
 metal clean1  b ! metal ne>e/ ! surface
 always conta9s m or less =eign  matt]4 
,illu/ration3 ,fig4 #f4 ,section ( ,soss
 ,die-ca/+ ,ma*9e    ,:ile ?is          
description ( ! op]ation ( ! die-ca/+   
ma*9e may  convey ! idea t ! process is 
a sl[ "o1 z a matt] ( fact1  ! "t       
requir$ is1 on ! av]age1 n ov] a m9ute &
 a half  = turn+ out a f9i%$ ca/+4 ,) ! 
ejection ( ! ca/+  f ! dies1 ! product  
is complet$1 9 !ory2 b 9 practice  !re  
are always a few small ?9 f9s1 caus$ by 
! air v5ts or by  improp]ly fitt$       
portions ( ! dies4 ,x is1 h[ev]1 b ! "w 
( a few seconds to break (f ^! f9s1 &   
unless !re are _m (  !m1 or !y are      
excessively ?ick1 !y are detrim5tal     
nei!r to  ! quality nor ! quantity (    

f9i%$ ca/+s4      ,po9ts on ! ,op]ation 
( ! ,die-ca/+ ,ma*9e    ,we h n[ tak5 up
 ! description & g5]al op]ation ( !     
die-ca/+ ma*9e1 b l e o!r ma*9e1 !re are
 num]\s  little k9ds & practices 9 its  
work+ ! obs]v+ ( :i* makes  ! diff]5ce  
betwe5 good & poor die-ca/+4 ,"s ( ^!   
po9ts  are "h giv54    ,! ca/+ ma*9e is 
be/ op]at$ by ?ree m51 "o ( :om att5ds  
to ! compression lev] & ! metal supply 9
 ! tank4 ,! o!r  two m5 /& on ea* side (
 ! die-end ( ! ma*9e1 & x is  _! duty to
 op]ate ! sprue-cutt]1 op5 ! dies &     
remove !  f9i%$ ca/+1 clean ! dies ) air
 & close !m1 ?r[ back  ! die-plates to  
_! ca/+ position ov] ! cyl9d] outlet1 & 
d any o!r "w incid5t to ! op]ation ( !  
ma*9e4 ,:ile x  requires ?ree m5 to     
op]ate a die-ca/+ ma*9e 9 ! be/ mann]1  
! man :o att5ds to ! compression lev]   
has a good deal ( sp>e  "t betwe5       
/rokes1 & if two or ev5 ?ree ( ! ma*9es 
are  conv5i5tly plac$1 "o man c easily  
pull lev]s = all ?ree4    ,! metal %\ld 
be kept j above ! melt+ po9t & at a     

uni=m temp]ature4 ,if ! metal is work$  
too cold1 ! result w  manife/ itself 9  
ca/+s t are full ( seams & creases1 & x 
w be difficult to 8fill0 ! ?9 places 9 !
 dies4 ,if1 on !  o!r h& ! metal is     
all[$ to get too hot1 ! die w ?r[       
excessively long f9s1 ! ca/+s w n cool z
 quickly 9 !  die1 & consequ5tly !y _c  
be made z rapidly4 ,on acc\nt (  !      
importance ( keep+ ! metal at a uni=m   
heat1 ! fre% metal  t is add$ to t 9 !  
tank f "t to "t1 is kept heat$ 9  a     
sep>ate furnace4 ,!re=e1 :5 ! metal 9 ! 
tank gets l[1 !  new supply does n r$uce
 ! temp]ature ( ! metal be+ work$4  ,"s 
ca/]s use a !rmomet] to indicate ! heat 
( ! metal4    ,ca/+-dies require        
lubrication frequ5tly4 ,j h[ (t5 !y %\ld
  be lubricat$ dep5ds on ! %ape ( ! die1
 ! composition ( !  ca/+ metal1 & !     
g5]al p]=mance ( ! dies4 ,beeswax is  ! 
common lubricant1 & ! lubrication       
consi/s 9 m]ely rubb+  ! cake ov] !     
surfaces ( ! dies t come 9 contact ) !  
ca/+ metal4 ,9 die-ca/+ l>ge p>ts1 !    

dies mu/ be kept cool  by "s artificial 
means1 = hot dies are conducive to sl[  
"w &  poor ca/+s4 ,to rea* ?is end1 l>ge
 dies are sometimes drill$ &  pip$ s t  
wat] may be circulat$ ?r\gh !m to keep  
!m cool4    ,9 ! ,soss ma*9e1 ! burn]s  
are s plac$ t ! metal 9 !  cyl9d] is    
kept at a slightly high] heat ?an t 9 ! 
tank  prop]4 ,?is condition is br\ght   
ab\t by hav+ ! cyl9d] directly  ov] !   
burn]s4 ,! value ( ?is feature lies 9 ! 
fact t  gas is n wa/$ 9 heat+ ! entire  
tank full ( metal to ?is  high] heat1 b 
/ill ! metal "u compression is at !     
requir$  temp]ature4 ,! gas consumption 
( ! av]age die-ca/+ ma*9e is  ab\t #ajj 
cubic feet p] h\r4    ,! spe$ at :i*    
die-ca/+s may be produc$ v>ies ) ! size 
(  ! ca/+s be+ made1 ! composition ( !  
metal be+ ca/1 &  ! /yle ( dies t mu/ be
 employ$4 ,9 _m cases1 9 die-ca/+1      
sep>ate brass or /eel pieces are us$1 t 
mu/ be plac$ 9 !  dies be=e ea* op]ation
 s t !y w be ins]t$ 9 & become  a "p ( !
 f9i%$ ca/+4 ,! dies may be difficult ( 

op]ation  on acc\nt ( draft problems or 
p9s & screws t mu/ be ins]t$  9 ! dies &
 remov$ f ea* ca/+ be=e ano!r c be made4
  ,^! diff]5t types ( dies w be m fully 
describ$ 9 ! next  *apt]4 ,tak5 z a     
:ole1 f t5 to sixty pieces p] h\r are ! 
maximum limits = spe$ 9 die-ca/+1 & ) a 
well-work+ die1  ( simple con/ruction1 a
 spe$ ( =ty pieces p] h\r is consid]$   
good production4 ,x is possible1 h[ev]1 
:5 ! ca/+s to be  produc$ are small 9   
size & simple 9 %ape1 to gate a numb] ( 
!m toge!r1 or r to con/ruct ! dies s t  
six or m  ca/+s may be made at once4 ,by
 ?is means x is (t5 possible to  ca/    
five or six ?\s& pieces p] day ( t5     
h\rs1 on a h&  die-ca/+ ma*9e4          
,,*apt] ,,ii    ,,mak+ ,,dies ,,=       
,,die-,,ca/+ ,,ma*9es      ,! mak+ (    
ca/+-dies calls = +5uity & skill ( !    
highe/  ord] on ! "p ( ! die-mak]4 ,!re 
is probably no class (  die-mak+ 9 :i* !
 "w produc$ is m fai?ful to ! dies1  bo?
 9 %[+ up ! little details 9 ! mak+ t   
reflect cr$it  on ! dies1 & 9 expos+ !  

defects & %ortcom+s 9 !  workman%ip1 if 
!re be any4 ,! ca/+s f ca/+-dies or     
molds  z !y are sometimes call$1 may be 
produc$ 9 dim5sions d[n to  t5-?\s&?s = 
accuracy if necess>y1 & once ! dies are 
made  ! ca/+s w n v>y 9 ! slighte/      
degree1 if ! work+  conditions are kept 
uni=m4    ,9 spite ( ! close "w requir$ 
9 mak+ ca/+-dies1 ! "w is  v fasc9at+4  
,p]haps x is on acc\nt ( ?is accuracy2  
possibly  x is on acc\nt ( ! fact t !y  
are made f ma*9e /eel2  b mo/ likely x  
is because !re are no h>d5+ tr\bles to  
be  cont5d$ )4 ,ano!r factor t makes !  
"w int]e/+ is !  +5uity requir$ 9 ! "w1 
= almo/ e die-mak]1 if he is  wor?y ( ! 
"n1 likes to figure out & plan = ! be/  
way (  build+ a die = a difficult job4  
,g5]al ,pr9ciples ( ,ca/+-die ,mak+     
,ca/+-dies1 or molds1 h little 9 common 
) s& molds4 ,x  is true t ! dies =      
die-ca/+ are compos$ ( two p>ts         
correspond+ to ! cope & n[el ( ! s&     
mold1 b !y are  s diff]5t 9 e o!r way t 
no b5efit w\ld result f a  comp>ison4   

,g5]ally speak+1 ca/+-dies are made (   
ma*9e /eel2 ! p>ts  :i* are exceptions  
are ! heavy bases & frames1 :i* are made
 (  ca/ iron1 & ! d[el p9s & small      
cores1 usually made ( tool  /eel4       
,except 9 r>e in/ances1 !re are no h>d5$
 p>ts ab\t a  ca/+-die2 ?is is ! case   
because ! melt+ po9ts ( "s ( !  alloys t
 are die-ca/ are high en\gh to draw !   
temp] f any  h>d5$ p>ts ( ! dies4    ,! 
ideal die is simple 9 con/ruction1 ) z  
few p>ts z  practicable2 ! ca/+s %\ld be
 easily eject$ & %\ld come  f ! dies z  
ne>ly free f f9s z possible4 ,to meet ^!
  requirem5ts 9 ! be/ way is !          
proposition t confronts !  +5uity ( !   
die-mak]4 ,z ! die is prim>ily 9 two    
p>ts1 !re  mu/ be a p>t+ l9e on ! ca/+4 
,?is l9e is always plac$ at  ! po9t t w 
p]mit ! ca/+ to be eject$ f ! dies 9  ! 
easie/ mann] possible1 be>+ 9 m9d !     
effect ! jo9t w  h on ! appe>ance ( !   
f9i%$ ca/+2 ?is is a po9t f>  less      
important ?an ) s& ca/+1 =1 if ! dies   
are prop]ly  made ?is seam w be b>ely   

p]ceptible4 ,:5 x is practicable to  d  
s1 x is wise to h ! p>t+ l9e come on an 
edge ( !  die-ca/+4 ,draft is unnecess>y
 on ! /raight 8up-&-d[n0  places1 b (   
c\rse x is impossible to draw any p>ts t
 are  und]cut4 ,means mu/ be provid$ =  
eject+ ! ca/+ f !  dies aft] completion 
& x is usually done by means ( ejector  
p9s1  ?\gh frequ5tly x is bett] to h !  
bottom ( ! die or "s  o!r section       
movable & d ! eject+ on ! same pr9ciple 
t  is us$ on draw+ dies ( ! comp\nd     
type4 ,on close "w1 %r9kage  plays an   
important "p1 & ! am\nt ( %r9kage v>ies 
f #j4jjb  to #j4jjg ( an in* p] in*4    
,alum9um %r9ks ! greate/ am\nt1  ,p>sons
 :ite brass %r9ks consid]ably1 :ile t9  
%r9ks b little4  ,?us1 x may be easily  
se5 t to figure ! %r9kage all[ance =  an
 alloy t conta9s ?ree or f\r metals )   
diff]5t %r9kages1  requires judgm5t4 ,to
 prev5t ! air f 8pocket+10 air v5ts are 
necess>y at frequ5t int]vals ar\nd !    
die-cavity4 ,^! v5ts are  made by mill+ 
a flat %all[ cut f ! die-cavity across !

 face  ( ! die to ! outside edges ( !   
block4 ,f  in* to  in*  is ! usual wid? 
& f #j4jjc to #j4jje ( an in*1 ! cu/om>y
  dep?1 v>y+ ) ! size & %ape ( ! die 9  
"q4    ,illu/ration3 ,fig4 #g4 ,disk ca/
 9 ,simple ,ca/+-die    ,! dies or molds
 = die-ca/+ are ( v>i\s /yles1 z are    
also  pun*-press dies1 & x w\ld be      
difficult to lay d[n specific  rules =  
_! classification4 ,!re are ! pla9 dies1
 )\t  complications ( any k9d2 slide    
dies ) "o or m slides2 dies  = be>+s1   
bo? ( ! 8half-r\nd0 & ( ! 8:ole-r\nd0   
types2  dies = gat$ "w2 & _m o!r less   
important classes4 ,!n !re  are dies t h
 features t belong to m ?an "o ( ^!     
types1 s t x is easily se5 t to decide  
^u ! /yle ( die  t w\ld be be/ = a giv5 
piece ( "w requires a good deal (       
exp]i5ce4 ,"s ( ! mo/ important ( ^!    
types c be/ be %[n  by illu/rat+ dies   
made 9 ! v>i\s /yles1 %[+1 /ep by /ep1  
h[ ! dies are made & assembl$4 ,to beg9 
)1 consid] ! mak+  ( a ca/+-die ( ! v   
simple/ =m4    ,9 ,fig4 #g is %[n a pla9

 flat disk made by die-ca/+4 ,9 actual  
practice1 a die w\ld n be made = su* a  
simple piece1 unless  !re 7 "s features 
ab\t x t w\ld prev5t x be+ made  on a   
screw ma*9e or ) press tools4 ,x might h
 a cam groove  cut 9 "o ( its flat      
sides1 ! sides might be cov]$ ) scroll  
"w1 !re might be ge> tee? ar\nd its     
circumf]5ce1 or a hundr$  & "o o!r      
conditions to make die-ca/+ a desirable 
me?od (  manufactur+4 ,all ^!           
complications are omitt$ = ! sake (     
simplify+ ?is initial description ( a   
ca/+-die4    ,illu/ration3 ,fig4 #h4    
,simple ,ca/+-die = ,ca/+ ,block %[n 9  
,fig4 #g    ,fig4 #h %[s ! die = ?is    
piece 9 plan & sectional elevation4  ,a 
is a squ>e ca/-iron frame1 made f a s+le
 ca/+4 ,?is frame  or box1 z x is       
g5]ally call$1 is plan$ on ! top &      
bottom  only4 ,next1 ! two die-halves ,b
 & ,c are %ap$ up f ma*9e  /eel4 ,9 ?is 
ca/+-die1 & 9 ! majority ( o!rs1 ^!  die
 blocks are squ>e4 ,! l[] half ( ! die  
,b is held to !  ca/-iron frame by      

filli/] head screws1 set 9 c\nt]bor$    
holes1  ?us s9k+ ! screw-heads "u !     
surface ( ! block4 ,! upp]  half ( ! die
 ,c is locat$ ^u ,b by d[el p9s driv5   
into ,b  :i* h a slid+ fit 9 ! ream$    
holes 9 ,c4 ,?is be+ done1  ! die-half  
,b is fix$ to ! faceplate ( ! la! & !   
recess  bor$ = ! die-cavity4 ,?is       
op]ation is a simple "o 9 ?is case1  = x
 is m]ely a /raight hole "o-half in*    
deep & ?ree in*es 9  diamet]4 ,( c\rse  
?is recess mu/ be c>efully f9i%$ ) a    
tool  t has be5 /on$ up to a %>p edge1  
us+ l>d oil4 ,em]y clo?  %\ld be us$ z  
little z possible4 ,x is unnecess>y to  
give ?is  hole draft1 b x mu/ be free f 
ridges or m>ks t w\ld prev5t  ! ca/+ f  
be+ pu%$ out4 ,if ! faces ( ! dies are  
spott$  ) a small piece ( box wood or   
ra:ide held 9 ! drill press &  kept *>g$
 ) fl\r em]y1 ! die-ca/+ w reproduce ?is
  8bird's-eye0 f9i% & ! appe>ance w well
 repay ! few m9utes  additional "t t x w
 take4 ,! spott+ %\ld be done ) dry     
em]y 7)\t oil7 to get ! brighte/ f9i%4  

,! upp] die-half ,c  is simply gr\nd on 
its work+ face4 ,! outside corn]s &     
edges (  ! faces ( bo? die-halves %\ld  
be well r\nd$ (f s z to insure  ! abs5ce
 ( slight d5ts or r\gh places t might   
prev5t ! dies  f fitt+ p]fectly4    ,!  
eject+ me*anism mu/ next be consid]$4   
,lev] ,d1 pivot$  f bracket ,e1 has a   
/eel p9 ,f t engages 9 ! elongat$  hole 
9 bracket ,g1 s t an upw>d pull ( ! lev]
 ,d raises  bracket ,g1 :i* is atta*$ to
 ejector-p9 plate ,h4 ,?is plate is  a  
loose fit ov] ! guide screws ,i t are   
atta*$ to ! l[]  die-half ,b4 ,! ejector
 p9s ,j1 f\r 9 numb]1 9 ?is die1 are    
rivet$ into ! ejector-p9 plate1 & !y "w 
?r\gh holes drill$  & ream$ ?r\gh ! l[] 
die-half4 ,! ends ( ^! p9s mu/ be  f9i%$
 (f s z to lie p]fectly flu% ) ! inside 
( ! die  :5 ready = op]ation &1 ( c\rse1
 !y mu/ be a slid+ fit 9  ! holes 9 !   
die4    ,an important feature ( a       
ca/+-die is ! sprue cutt]1 %[n 9  ?is   
die at ,k4 ,if ! disk = :i* ?is die 0   
made1 _h _h a  hole or c5tral op5+ ( any

 k9d1 ! sprue cutt] w\ld be/ be  op]at$ 
at t po9t2 b1 z ?is disk is pla91 !     
sprue cutt]  mu/ be plac$ at ! edge4 ,at
 ! outside ( ! die-cavity1 z %[n  9     
,fig4 #h1 ! op5+ = ! sprue cutt] is laid
 out1 drill$  & fil$ to %ape4 ,x is     
obvi\s t ! side ( ! sprue cutt]  adjac5t
 to ! die mu/ fit ! outl9e ( ! die      
p]fectly1 s t  !re w be no break 9 !    
appe>ance ( ! ca/+4 ,! op5+  = x is     
ext5d$ ?r\gh ! upp] die-half1 & f a po9t
  ( an  in* f ! inside face ( ! die ?is 
hole is fl>$ out ne>ly z  l>ge z ! op5+ 
?r\gh ! die-plate ( ! ma*9e4 ,( c\rse  !
 app]ture 9 ! upp] die-half mu/ be no   
l>g] ?an ! op5+  ?r\gh ! die-plate2     
o!rwise ! sprue c\ld n be pu%$ out4 ,!  
sprue cutt] itself is a long rod1 ^:    
section is ( ! same %ape  & size z !    
op5+s j made1 & x is connect$ to ! sprue
  cutt+ me*anism ( ! ma*9e4 ,( c\rse x  
is unnecess>y to %ape  ! entire l5g? ( !
 sprue cutt] to size2 aft] ! work+ end  
is  mill$ to %ape = a di/ance ( six or  
eight in*es1 ! re/ ( !  rod may be left 

r\nd4 ,! sprue cutt] is f9i%$ fir/1 aft]
 :i*  bo? ! op5+s 9 ! die are fitt$ to  
x2 & :ile ! fit %\ld  be metal tight1 x 
mu/ be p]fectly free to slide4    ,!    
dies are m\nt$ on ! die-plates ( ! ca/+ 
ma*9e by means  ( /raps1 mu* ! same z   
bol/]s are held on pun* press b$s4 ,!   
position ( ! die on ! die-plate mu/ be  
su* t ! op5+ =  ! sprue cutt] w l9e up )
 ! nozzle at ! outlet ( !  cyl9d]4 ,at !
 "t ( ca/+1 ! position ( ! sprue cutt]  
is  z %[n 9 ! illu/ration ( ?is die1    
,fig4 #h4 ,9 ?is position  !re is room =
 ! metal to ent] ! die-cavity1 & yet !re
 is  b a small am\nt ( metal to be cut  
(f & pu%$ back aft] ! die  has be5 fill$
 ) metal4    ,) slight modifications1 ! 
above /yle ( die may be us$ =  die-ca/+ 
any piece t w draw or pull out ( a      
two-"p die4 ,if  holes mu/ be ca/ ?r\gh 
! piece1 x is only necess>y to add core 
p9s to ! l[] die ,b1 a po9t t w be m    
fully describ$  lat]4 ,x is unnecess>y  
to add t bo? halves ( ! die may be      
utiliz$ 9 mak+ ! cavity = ! die1 %\ld !y

 be ne$$4 ,also1  x is (t5 easi] to     
ma*9e out ! recess l>g] ?an is ne$$1 &  
set 9 pieces 9 :i* p>ts ( ! outl9e ( !  
die-ca/+ h  be5 =m$4 ,ge> tee? are put 9
 ! die 9 ?is way2 a broa* is cut  simil>
 to ! ge> desir$1 !n h>d5$ & driv5 ?r\gh
 a piece  ( /eel plate :i* is aft]w>d   
fitt$ to its place 9 ! die4      ,slide 
,dies    ,! die illu/rat$ 9 ,fig4 #i is 
"o ( ! mo/ successful ( !  v>i\s types (
 ca/+-dies1 & if prop]ly made is an     
int]e/+  piece ( die "w4 ,! pr9cipal use
 ( ?is p>ticul> /yle ( die1  call$ a    
slide die1 is to ca/ p>ts l ! "o %[n 9  
,fig4 #aj1  :i* is a disk simil> to ! "o
 :i* ! la/ die describ$ 0  to ca/1      
except t x has rais$ lett]s at ! edge & 
a hole 9  ! c5t]4 ,x is obvi\s t ! die  
la/ describ$1 7,fig4 #h71 w\ld  n d =   
disks or o!r pieces hav+ projections or 
depressions  ar\nd _! edges1 z1 =       
in/ance1 pr9t+ or c\nt+ :eels )  rais$  
or sunk5 *>act]s1 or groov$ pulleys4    
,briefly1 ?is /yle  ( die is simil> to !
 simple ca/+-die1 except t slides are   

provid$1 to ! requir$ numb]1 :i* =m !   
edge ( ! ca/+4  ,a die = a pla9 groov$  
pulley w\ld require b two slides1 :ile  
a die = a pr9t+ :eel ) =ty lett]s ar\nd 
its edge w\ld  necessitate =ty slides1  
"o = ea* ( ! lett]s4 ,! die ab\t to  be 
describ$1 %[n 9 ,fig4 #i1 0 made to ca/ 
a :eel ) six rais$  lett]s4    ,ref]r+  
to ,fig4 #i1 ,d is ! ca/-iron box or    
frame1 ,e1 ! l[]  die1 & ,f ! upp] die4 
,9 mak+ ! l[] die-half1 ! /ock is  fir/ 
%ap$ to size & d[el$ to ! blank = ! upp]
 die-half1  & ! holes = atta*+ to !     
frame are drill$4 ,= ! sake (  cle>ness1
 ^! holes & screws are omitt$ f !       
illu/ration z  are also ! v5ts1 s9ce !y 
h be5 fully expla9$4 ,! l[]  die is next
 /rapp$ to a faceplate1 tru$ up1 & bor$ 
out ne>ly  to ! diamet] ( ! body ( !    
piece to be ca/1 exclusive ( !  rais$   
lett]s4 ,! dep? ( ?is recess is equal to
 ! ?ickness (  ! pr9t+ :eel plus #c_/af 
in* to all[ = ! cam r+ ,g t is  us$ to  
reciprocate ! slides ( ! die4 ,! cam r+ 
is made l>ge  en\gh to cov] ! die-cavity

 z well z ! slides t surr\nd  x1 ) an   
all[ance ( an in* or two = ! cam slots  
,h4 ,! six  slides ,i are made long     
en\gh to h good be>+ surfaces4 ,) !     
size ( ! cam r+ det]m9$1 ! die is next  
bor$ out to receive  ?is cam r+ & ! la/ 
in* ( ! recess is c>ri$ d[n to !  dep? (
 ! die cavity s z to make an end+ space 
= ! slots  t ! slides are to "w 94 ,!   
die is n[ tak5 f ! faceplate  & ! slots 
= ! slides laid out4    ,illu/ration3   
,fig4 #i4 ,slide ,die = ,ca/+ ! ,pr9t+  
,:eel %[n  9 ,fig4 #aj    ,^! slots may 
be mill$ or %ap$1 b mill+ is to be      
pref]r$4  ,! next /ep is ! mak+ & fitt+ 
( ! slides1 :i* are (  ma*9e /eel1 hav+ 
a good slid+ fit 9 ! slots4 ,! six      
slides  are fitt$ 9 position & left ) ! 
ends project+ into ! die  prop]4 ,!     
slots ,h are next pr(il$ 9 ! cam r+ ,g1 
& !  p9s ,j t "w 9 !m are made & driv5  
into ! holes 9 !  slides4 ,) ! slides & 
cam r+ 9 place1 ! cam r+ is rotat$  to  
br+ all ! slides to _! inn] position :]e
 !y are held  tempor>ily by means ( !   

cam r+ & tempor>y screws4 ,! die-half  )
 ! slides ?us clamp$ 9 ! inn] or clos$  
position1 is set up  on ! la! faceplate 
& ! die-cavity indicat$ up & bor$ out to
  ! f9i% size1 :i* op]ation also f9i%es 
! ends ( ! slides  to ! prop] radius4 ,!
 die may n[ be tak5 d[n & ! slides      
remov$ to engrave ! lett]s ^u _! concave
 ends4 ,! engrav+  c be done 9 ! be/    
mann] on a ,gorton engrav+ ma*9e1 b if  
su* a ma*9e is n available !y may be cut
 9 by h&4 ,/amp+  %\ld nev] be resort$  
to = putt+ 9 ! lett]s1 because !  /ock  
displacem5t w\ld be s great t x w\ld be 
impossible to  ref9i% ! surface to its  
orig9al condition4 ,be=e fitt+ !  cam   
r+1 an op5+ mu/ be mill$ 9 ! die to all[
 ! h&le to  be rotat$ ! %ort di/ance    
necess>y4 ,aft] ! cam r+ has be5  fitt$1
 x is held 9 by ! f\r small /raps ,k1   
atta*$ by screws  to ! l[] die-half at !
 corn]s4    ,illu/ration3 ,fig4 #aj4    
,pr9t+ ,:eel ca/ 9 a ,slide ,die    ,!  
sprue cutt]1 :i* is n %[n1 is op]at$    
?r\gh ! hole  9 ! c5t] ( ! piece & is1 (

 c\rse1 r\nd 9 ?is die4  ,its action is 
! same z 0 ! "o previ\sly describ$1 & ! 
eject+ device is simil>1 ) ! exception t
 ! brackets ,l  t are atta*$ to !       
ejector-p9 plate ,m1 are widely sep>at$ 
s  z to make room = ! sprue cutt] t     
works ?r\gh a hole 9 !  plate ,m4       
,die = ,ca/+ ) ,ins]t$ ,pieces    ,=    
mak+ die-ca/+s t are to h pieces ( ano!r
 metal  ins]t$1 x is necess>y to h a die
 ) provisions = receiv+  ! metal blank &
 hold+ x firmly 9 position :ile ! metal 
is  be+ ca/ ar\nd x1 & ( c\rse ! piece  
mu/ be held 9 su* a  mann] t x c be     
easily )drawn f ! die ) ! f9i%$  ca/+4  
,! die illu/rat$ 9 ,fig4 #aa is = a "p t
 is us$ z a sw++  weight1 %[n 9 ,fig4   
#ab4 ,! upp] "p ( ! piece is made f a   
%eet /eel pun*+1 s z to light5 ?is "p ( 
! piece z well  z to give increas$      
/r5g?1 especially at ! hole at ! pivot$ 
end ( ! "w4 ,! ca/ portion ( ! piece is 
slott$ l5g?wise1  z ! illu/ration %[s2 &
 ?ree holes pass ?r\gh ! ca/+1  pi]c+ ! 
sides ( ! slot4 ,9 addition to %[+ !    

me?od (  mak+ dies = ins]t$ pieces1 ?is 
die %[s ! pr9ciples (  simple cor+4     
,illu/ration3 ,fig4 #aa4 ,ca/+-die =    
,mak+ ,ca/+s ) ,ins]t$  ,pieces l t %[n 
9 ,fig4 #ab    ,9 mak+ ?is die1 two     
ma*9e-/eel blanks are plan$ up = !  upp]
 & l[] halves ( ! die1 ,a & ,b1 ! l[]   
die be+  made ne>ly twice z ?ick z !    
upp] die because x is 9 ?is "p  t ! mo/ 
( ! die-cavity w be made4 ,9 ?is l[]    
half (  ! die ! /ock is mill$ out to !  
same %ape z ! outl9e (  ! plan view ( ! 
ca/+1 be+ c>ri$ d[n to ! exact dep?  ( !
 ?ickness ( ! ca/+4 ,f ! wide end ( ?is 
recess !  /ock is mill$ or %ap$ out 9 a 
p>allel slot to ! outside ( !           
die-block4 ,at ! bottom ( ! side ( ?is  
wide slot are ,t-slots  to guide ! slide
 ,e t is to "w 9 ?is op5+4 ,! side is   
mill$ & fitt$ to ! ,t-slots & op5+ 9 !  
die1 b is left  consid]ably long] ?an ! 
f9i% size4 ,next1 ! slide is m\nt$  on !
 faceplate ( a la! & turn$ out on ! end 
) ! prop]  radius & a tongue to =m !    
slot t is to be 9 ! curv$ end  ( ! ca/+4

 ,at ! out] end ( ! slide is left a lug 
t is  drill$ & tapp$ = ! op]at+ lev] ,f 
t reciprocates !  slide1 us+ ! /ud 9    
bracket ,k z a fulcrum4    ,two pieces (
 ma*9e /eel are next %ap$ & f9i%$ up to 
=m !  *amf]$ "p ( ! ca/+ & to locate !  
ins]t$ /eel pun*+  9 ! die4 ,! comb9$   
?ickness ( ^! pieces ,c & ,d is equal   
to ! ?ickness ( ! ca/+1 less ! ?ickness 
( ! ins]t$  piece4 ,x is n[ an easy     
matt] to seat section ,d 9 ! bottom (  !
 mill$ "p ( ! l[] die-half1 & to locate 
section ,c 9 its  prop] position on !   
upp] half4 ,a pilot p9 ,m is fitt$ 9 ,d 
to  hold ! /eel pun*+ 9 position by     
means ( ! hole t is 9 !  extreme upp]   
end ( ! pun*+4 ,! pilot p9 ext5ds ?r\gh 
?is  hole into a correspond+ hole 9     
section ,c4 ,at ! l[] end ( !  /eel "p t
 is ins]t$1 !re are two holes ! object (
 :i*  is to secure ! pun*+ to !         
die-ca/+1 = ! molt5 metal  runs ?r\gh ^!
 holes1 practically rivet+ ! die-ca/+ to
 !  ins]t$ piece4    ,illu/ration3 ,fig4
 #ab4 ,die-ca/ ,weight ) ,ins]t$        

,%eet-/eel  ,pun*+    ,provision has n[ 
be5 made = hold+ ! %eet-metal "p t is   
to be ins]t$1 & ! cavity has be5        
complet$ = ! ca/+1  includ+ ! tongue at 
! end2 x n[ rema9s to describe ! mann]  
( =m+ ! holes t pi]ce ! ca/+ ?r\gh !    
slott$  portion4 ,9 ! l[] die-half !    
positions ( ! ?ree holes ,h are  laid   
out1 drill$ & ream$4 ,!n1 ) ! two       
die-halves toge!r  & ! slide clamp$ at  
its inn] position1 ! holes are transf]r$
  ?r\gh ! slide & ! upp] die4 ,?is be+  
done1 x is an easy  matt] to make core  
p9s & drive !m into ! upp] die at ! two 
end holes1 ! c5t] hole be+ tak5 c>e ( by
 ! sprue cutt] ,l  t w be describ$ lat]4
 ,! core p9s %\ld be a nice slid+  fit  
?r\gh ! slide & 9 ! holes 9 ! l[] die1  
into :i*  !y %\ld ext5d f a qu>t] to    
half an in*4 ,9 addition to  cor+ !     
holes1 ^! p9s act z a lock to hold !    
slide ,e 9 its  prop] position at ! "t (
 ca/+4    ,! sprue cutt] ,l is mo/      
conv5i5tly op]at$ 9 ! c5t] hole1  ?us   
do+ away ) ! core p9 t w\ld o!rwise be  

requir$4 ,!  sprue cutt] ne$s little    
description 9 ?is die1 = z 9 ! slide    
die1 x is m]ely a pla9 r\nd rod t fits  
closely 9 ! holes  ?r\gh ! dies & slide4
 ,! ejector me*anism is ! same 9 ?is    
die z 9 ! dies already describ$2 !re=e  
fur!r description is  unnecess>y4       
,illu/ration3 ,fig4 #ac4 ,ca/+-die = !  
,half-r\nd ,be>+ %[n 9  ,fig4 #ad    ,! 
op]ation ( ?is die is v simple4 ,!      
%eet-/eel piece is laid  9 ! recess 9 ! 
op5 die1 be+ locat$ by ! p9 ,m4 ,slide  
,e is ?r[n 9 by means ( lev] ,f1 & !    
dies are clos$4 ,at  ! "t ( ca/+1 !     
sprue cutt] 9 is ! position %[n 9  !    
sket*1 be+ ne>ly ?r\gh ! die-cavity4 ,z 
be=e expla9$1  ?is position admits !    
molt5 metal to pass into ! die-cavity1 b
  /ill leaves v little sprue to be cut  
(f aft] ! die-ca/+ is  complet$4 ,x %\ld
 be /at$ t ! /eel piece t is ins]t$  mu/
 be p]fectly flat & free f burrs t w\ld 
prev5t !  die-halves f com+ toge!r      
prop]ly4      ,be>+ ,dies    ,be>+ dies 
are "o ( ! mo/ important ( ! v>i\s      

classes (  ca/+-dies4 ,! be>+s produc$  
by die-ca/+ are s f> sup]ior  to ^? made
 by o!r ca/+ me?ods & ma*9+ t _! use is 
n[ v ext5sive4 ,dies are made =         
8half-r\nd0 & 8:ole-r\nd0  be>+s4 ,!re  
is little out ( ! ord9>y ab\t a         
:ole-r\nd die1  b ! half-r\nd die       
involves _m int]e/+ me?ods ( die-mak+1  
& = t reason is "h describ$4    ,fig4   
#ac %[s a ca/+-die = half-r\nd be>+s4   
,half-r\nd be>+  dies are usually made  
to ca/ two be>+s at a "t1 = ! reason  t 
x is j z easy to ca/ two pieces ( su* a 
%ape z x is to  ca/ "o1 &1 9 addition1 !
 die is balanc$ 9 a bett] mann]4 ,z  )  
o!r dies1 ! fir/ /ep is to ma*9e up !   
frame ,a & !  two die-halves ,b & ,c4 ,!
 pieces ,d & ,e t are to =m  ! insides (
 ! be>+s are !n turn$ up & "o side ( ea*
  %ap$ & key$ to fit ! slots t h        
previ\sly be5 mill$ 9  die-half ,c4 ,^! 
p>ts are held 9 place by d[els & screws4
 ,"o  ( ! be>+s produc$ by ?is die is   
%[n 9 ,fig4 #ad1 & x w  be notic$ t !re 
is an oil groove )9 t cov]s ! l5g?  ( ! 

be>+4 ,to produce ?is groove 9 !        
die-ca/+s1 a %ell  mu/ be turn$ up &    
bor$ out ^: inside diamet] is t ( !     
inside ( ! be>+1 & ^: ?ickness equals ! 
dep? ( ! oil  groove4 ,?is be+ done1 !  
oil grooves are laid out ^u ! %ell  &   
cut out by drill+ & fil+4 ,aft] r\nd+ ! 
outside corn]s1  ^! little /rips are    
p9n$ to ! cores ,d & ,e 9 _! prop]      
places4    ,illu/ration3 ,fig4 #ad4     
,die-ca/ ,half-r\nd ,be>+1 ,%[+ ! ,ca/  
,oil ,grooves    ,ano!r little k9k 9 ?is
 connection is wor?y ( not+4 ,s _m      
diff]5t /yles & sizes ( be>+s are made  
by a conc]n do+ mu*  die-ca/+ t x is    
ess5tial t ! die-ca/ be>+s %\ld  be> "s 
di/+ui%+ numb] to id5tify !m4 ,z ?is    
numb] is  ( no consequ5ce to ! us] x is 
well to h ! numb] 9 an  inconspicu\s    
place1 b x mu/ be :]e x w n be effac$ by
  scrap+1 etc4 ,be>+ 9 m9d t x is mu*   
easi] to produce rais$  lett]+ by       
die-ca/+ ?an to produce sunk5 lett]+1 x 
w be  readily se5 t ! oil groove af=ds a
 good place 9 :i* to  put ! be>+ numb]4 

,?is is easily done by /amp+ ! figures  
^u ! n>r[ /rip t =ms ! oil groove4 ,9   
?is place on !  be>+ x may be easily    
f\nd if ne$$1 & ( c\rse !re is no  dang]
 ( its be+ tak5 out by ma*9+4    ,! l[] 
die consi/s ( two blocks ,f & ,g1 ea* ( 
:i*  conta9s an impression ( a be>+4 ,! 
be/ way to make ^! p>ts  is to lay out !
 ends ( ea* ( ! blocks ) ! prop] radius1
  tak+ c>e to h ! c5t] come a little    
bel[ ! surface ( !  face ( ! block4 ,!n 
! blocks %\ld be %ap$ out to get ! bulk 
( ! /ock out1 be=e sett+ up 9 ! la!4    
,aft] ! la! "w  is done on ea* piece1   
:i* ( c\rse is usually done sep>ately1 !
  faces ( ! two blocks are fac$ d[n j to
 ! exact c5t] ( !  impression4 ,x w be  
notic$ t two blocks are us$ = ! l[]  "p 
( ! die4 ,! reason is to facilitate !   
locat+ ( ! female  p>ts ( ! die 9 prop] 
relation to ! male p>ts4 ,aft] prop]ly  
locat+1 !y may be d[el$ & screw$ to     
baseplate ,b4    ,illu/ration3 ,fig4    
#ae4 ,int]e/+ ,examples ( ,die-ca/+s    
,! sprue cutt] ,h1 bett] %[n 9 ! plan   

view1 is squ>e 9 %ape  & connects ) !   
die-cavities 9 a ?9 n>r[ op5+ on ei!r   
side ( ! sprue cutt]4 ,! ejector p9s1   
,i1 two to ea* die1 are  at ! ends ( !  
be>+s4 ,! ejector-p9 plate ,j is        
necess>ily  l>ge1 & is op]at$ by lev]   
,k4    ,fig4 #ae %[s a numb] ( int]e/+  
examples ( die-ca/+s4          ,,*apt]  
,,iii    ,,van ,,wagn] ,,mfg4 ,,co4',s  
,,die-,,ca/+ ,,practice      ,9 #aijg1  
,mr4 ,e4 ,b4 ,van ,wagn]1 ( ,syracuse1  
,n4 ,y41 e/abli%$ !  ,e4 ,b4 ,van ,wagn]
 ,mfg4 ,co4 = ! production ( die-ca/+s4 
,!  factory comprises ! (fice section1 !
 ma*9e %op :]e ! dies  & ca/+ ma*9es are
 built1 ! metallurgical laboratory :]e !
  metals are alloy$1 ! ca/+ dep>tm5t %[n
 9 ,fig4 #ag :]e !  die-ca/+s are made1 
& ! trimm+ dep>tm5t4      ,possibilities
 & ,limitations ( ,die ,ca/+            
,illu/ration3 ,fig4 #af4 ,die-ca/+      
,con/ructions to be avoid$    ,at !     
outset we may say t x is possible to    
die-ca/ almo/ any  piece1 b x is n by   
any means practicable to d s4 ,x mu/ be 

rememb]$ t to die-ca/ on a practical    
basis ! dies mu/ be  con/ruct$ 9 su* a  
mann] t ! co/ ( _! op]ation &  up-keep w
 be light1 or !re w be no pr(it 9       
die-ca/+4 ,x  is impracticable to       
produce "u-cut "w1 t is1 "w hav+ no     
draft & :i* is !re=e impossible to draw 
f ! die4 ,su*  an in/ance is t illu/rat$
 at ,a1 ,fig4 #af1 & by ! int]nal       
section ( ,m1 ,fig4 #ba1 & ! int]nal    
groove 9 ,o1 also %[n  9 ,fig4 #ba4 ,if 
absolutely necess>y1 "w ( ?is k9d c be  
done by  ! use ( collapsible cores2 b   
"h1 aga91 we meet resi/ance 9  ma9ta9+ !
 dies 9 prop] condition1 &1 moreov]1 ?is
 me?od  is comm]cially impracticable1   
ow+ to ! difficulty ( op]at+  ^! cores  
rapidly4 ,holl[ "w1 requir+ curv$ cores1
 l faucets  & b5t pip+ ( ! "* illu/rat$ 
at ,c 9 ,fig4 #af1 are  difficult to    
produce4 ,if1 9 design+ ! piece1 x c be 
plann$ to  h ! p>ts ( su* a %ape t !    
cores c be readily )drawn1  employ+ a   
two-piece core ) a slight draft 9 ea*   
direction1  ! division com+ z indicat$  

by ! core l9e ( ,c 9 ,fig4 #af1  !      
problem becomes simpl]4 ,(t5times ?is "w
 c be/ be done  by ca/+ 9 a /raight     
piece1 aft]w>d b5d+ ! die-ca/+4  ,x does
 n pay to ca/ r\gh heavy "w t c be made 
j z  effici5tly by s& ca/+4 ,g5]ally    
speak+1 ! greate/ sav+  c be effect$ by 
die-ca/+ small pieces :i* h previ\sly   
requir$ a l>ge am\nt ( ma*9+ to produce4
 ,on l>ge pla9 "w  ! am\nt ( metal      
requir$ = ! ca/+ makes ! co/ excessive  
on acc\nt ( ! diff]5ce 9 co/ ( ! metals4
 ,if1 h[ev]1 !  l>ge "w mu/ be f9ely    
f9i%$ by poli%+1 etc41 x is (t5times    
f\nd ( advantage to die-ca/4 ,corn]s1   
especially ^? jo9+ ?ick  & ?9 sections1 
z at ,b1 ,fig4 #af1 %\ld be heavily     
fillet$  z %[n on "o side ( ?is piece4  
,reg>d+ ! ca/+ ( ?9  sections1 x is n   
practicable to try to ca/ sections "u   
#c_/fd  in* 9 ?ickness1 z ! metal runs )
 difficulty into su* n>r[  places4 ,a   
ca/+ hav+ walls #a_/af in*1 l t %[n at  
,x1 ,fig4  #bd1 is easily ca/4 ,?read$  
sections1 if ! ?reads are f9e1 say1  "u 

tw5ty-f\r to ! in*1 %\ld n be die-ca/1  
because "u  mod]ate pressure !y w /rip4 
,a good way to treat con/ructions (  ?is
 k9d is to enclose brass or /eel bu%+s 9
 ! die-ca/+s 9  :i* ! ?reads are        
requir$4    ,illu/ration3 ,fig4 #ag4    
,view ( ! ,ca/+ ,room    ,z to !        
accuracy ) :i* die-ca/+s may be produc$1
 x is  possible to keep dim5sions )9    
#j4jjje in* ( /&>d size1 b to  d s      
requires consid]able exp5se 9 keep+ !   
dies 9 condition4  ,a limit ( #j4jjb    
in*1 h[ev]1 is entirely practicable1 & c
 be  ma9ta9$ easily4 ,9 specify+ !      
accuracy ) :i* die-ca/+s  are to be     
made1 only ^? p>ts :i* are absolutely   
ess5tial %\ld  be held to size1 9 ord]  
to keep ! co/ ( ! "w nom9al4 ,"o (  !   
great advantages ( ! use ( die-ca/+s is 
t no f9i%+ is  requir$ aft] ! pieces    
leave ! molds4 ,f9i% requirem5ts %\ld   
be pla9ly /at$ 9 ord]+ die-ca/+s1 z !   
alloy mu/ be suit$  to ^! requirem5ts4  
,illu/ration3 ,fig4 #ah4 ,me?ods (      
atta*+ ,die-ca/ ,ge>s1 etc41 to  ,%afts 

,ano!r great sav+ is effect$ on lett]$  
"w1 ei!r rais$ or  sunk54 ,"o ( ^! jobs 
is illu/rat$ at ,q1 ,fig4 #bb1 :i* %[s  
an example ( die-ca/ lett]+4 ,sunk5     
lett]+ is to be pref]r$  to rais$       
lett]+1 z ! latt] is m easily injur$4   
,knurl$  "w may be produc$ easily1 if   
/raight knurls are us$1 & ?read$        
sections ov]  in* 9 size are entirely   
practicable1 ei!r int]nal  or ext]nal4  
,ext]nal die ca/ ?reads are illu/rat$ at
 ,r & ,s1  ,fig4 #bb4 ,! ca/+ ( ge>s &  
segm5ts is a famili> application  (     
die-ca/+2 ?is is illu/rat$ by ! l>ge ge>
 at ,n1 ,fig4 #ba1  & ! segm5t at ,w1   
,fig4 #bc1 :i* give an idea ( ! g5]al   
"* ( ?is class ( "w4 ,! ca/+ ( pulleys1 
ge>s1 &  simil> p>ts on %afts may be    
easily effect$ z %[n by ! ge> on  ! %aft
 at ,n1 9 ,fig4 #ba4 ,! views %[n 9     
,fig4 #ah are int5d$  to convey an idea 
( ?ree me?ods ( die-ca/+ ar\nd %afts4   
,at  ,d is %[n a die-ca/+ ca/ ar\nd a   
/eel %aft4 ,if ! surface  ( ! %aft com+ 
)9 ! pulley has be5 previ\sly knurl$1  !

 pulley w grip x mu* bett]1 b = ord9>y  
purposes !  %r9kage ( ! die-ca/ metal   
ar\nd ! %aft is suffici5t4 ,if any      
heavy /ra9 is to be impos$ on ! "w1 x is
 bett] to provide  an*or holes ?r\gh !  
%aft1 l ^? indicat$ at ,e4 ,x w be      
readily se5 t ! die-ca/ metal runs ?r\gh
 ^! holes 9 !  %aft1 =m+ rivets :i* are 
integral ) ! ca/+4 ,= locat+  lev]s ^u !
 ends ( %afts1 etc41 a good way is to   
flatt5 opposite  sides ( ! %aft & ca/   
ar\nd !m1 z %[n at ,f1 ,fig4 #ah4 ,!    
screw se5 project+ b5ea? ! piece at ,q1 
,fig4 #bb1 0 die-ca/  9 place4 ,any ( ^!
 me?ods are to be recomm5d$1 & a prop]  
k ( possibilities ( ?is k9d w increase !
 scope (  die-ca/+4    ,illu/ration3    
,fig4 #ai4 ,a ,few ,possibilities ( ,die
 ,ca/+    ,ano!r phase ( die-ca/+ :i* c 
well be borne 9 m9d is !  possibility ( 
ins]t+ /eel or o!r p>ts 9 ! die-ca/+4   
,su* an in/ance is %[n at ,g 9 ,fig4    
#ai--;a die-ca/+ :i* 0  made by ! ,van  
,wagn] ,co4 z a "p ( an electrical      
app>atus1 !  /eel ins]ts be+ contact    

po9ts4 ,(t5times x is f\nd advisable  to
 include brass be>+ r+s to give         
additional durability at po9ts  :]e !   
die-ca/ metal w\ld n /& up4 ,! die-ca/+ 
%[n at  ,u1 ,fig4 #bc1 9 :i* ! brass r+ 
at ,t has be5 incorporat$1  is typical (
 su* cases4 ,to die-ca/ pieces l ^? %[n 
at  ,h 9 ,fig4 #ai1 & simil>ly at ,v 9  
,fig4 #bc1 hav+ inv]t$  conical op5+s1  
might at fir/ ?\ght seem difficult1 b   
?is is  entirely practicable4 ,simil>ly1
 split bu%+s l ^? %[n at  ,i1 ,fig4 #ai1
 & at ,w1 ,fig4 #bc1 may be ca/ )       
project+ lugs  = ! reception ( screws = 
clamp+ ^u %afts1 etc41 b ?is            
con/ruction %\ld n be us$ if frequ5t    
tight5+ or loos5+  w be necess>y4       
,illu/ration3 ,fig4 #bj4 ,ca/+s :i*     
illu/rate ,po9ts ( ,%r9kage  & ,draft   
,illu/ration3 ,fig4 #ba4 ,die-ca/+s %[+ 
,impractical ,"u-cut  ,sections2 also a 
,l>ge ,ge> die-ca/ on ,%aft             
,illu/ration3 ,fig4 #bb4 ,die-ca/+s :i* 
%[ ,lett]+ & ,?read  ,ca/+s    ,!       
%r9kage problem manife/s itself 9       

die-ca/+ 9 ! same  measure t x does 9   
o!r ca/+ op]ations4 ,diff]5t metals     
%r9k 9 diff]5t degrees1 z w be expla9$  
lat] on4 ,h[ev]1  "o important po9t c be
 m5tion$ at ?is "t3 t is1 ! am\nt  (    
%r9kage is (t5 dep5d5t ^u ! %ape ( !    
piece4 ,=  in/ance1 pieces l ^? %[n at  
,k 9 ,fig4 #bj or at ,x 9 ,fig4  #bd1 w 
%r9k v little on acc\nt ( ! fact t !    
/eel mold  is ( su* %ape t ! c5tral core
 w prev5t ! die-ca/+  f %r9k+4 ,h[ev]1  
pieces l ^? %[n at ,l 9 ,fig4 #bj1  or  
at ,v 9 ,fig4 #bd1 :i* h no?+ to hold !m
 f pull+  toge!r z !y cool1 w %r9k to ! 
greate/ ext5t4 ,all (  ^! po9ts mu/ be  
tak5 into consid]ation :5 design+ "w =  
die-ca/+4 ,practically no draft is      
necess>y on a die-ca/+1 except  on v    
deep sections1 z indicat$ at ,j 9 ,fig4 
#bj1 :]e a draft  ( #j4jja in* to ! in* 
is desirable4 ,p]fectly /raight         
sections1  h[ev]1 c be ca/1 z ! %r9kage 
( ! metal is usually en\gh  to free x f 
! die4    ,illu/ration3 ,fig4 #bc4      
,typical ,die-ca/+s illu/rat+ ,v>i\s    

,po9ts    ,illu/ration3 ,fig4 #bd4      
,die-ca/+s illu/rat+ ! ,extremes (      
,%r9kage    ,x is ! op9ion ( ! ,van     
,wagn] ,co4 t die-ca/+ co/s c  be       
mat]ially r$uc$ if design]s w be> ?is   
po9t 9 m9d :5  br++ out new designs4    
,ev5 ?\gh x is (t5 possible to ca/      
special pieces1 incorporat+ sev]al p>ts 
9 "o1 & !reby  accompli%+ :at seems to  
be a great /unt to ! design]1 x is      
sometimes m practicable to make ! piece 
9 sev]al sections &  lat] assemble x4 ,n
 only is ?is simpl] = ! die ca/]1 b x   
is also m economical = ! cu/om]4 ,su*   
po9ts z avoid+ ?9  sections1 includ+    
l>ge fillets at corn]s1 z well z tak+   
acc\nt  ( ! "u-cut problem1 are simply  
matt]s ( common s5se1 b !y  c pr(itably 
be consid]$ by ! design]4      ,! ,van  
,wagn] ,die-ca/+ ,ma*9e    ,! fir/      
ess5tial to good die-ca/+ is a good ca/+
 ma*9e4  ,p]haps ! be/ kn[n types ( ca/+
 ma*9es are ( ! famili>  plung] type1 ( 
:i* !re are sev]al v>ieties1 ! pneumatic
 type  & ! rot>y or automatic type4 7,= 

descriptions ( v>i\s types (  die-ca/+  
ma*9es1 see 8,die ,ca/+ ,ma*9es10       
,,ma*9]y',s ,ref]5ce  ,book ,no4 #ajh47 
,= ! economical production ( die-ca/+s1 
h[ev]1  ! h&-op]at$ ma*9es are r too    
sl[1 & automatic ma*9es  are applicable 
only to a class ( "w :i* may be made 9 v
 l>ge  quantities4 ,= ^! reasons1 !re=e1
 ! ,van ,wagn] ,co4 employs  ! compress$
 air type ( die-ca/+ ma*9e :i* 0 pat5t$ 
by  ,mr4 ,e4 ,b4 ,van ,wagn] 9 #aijg4 ,9
 ! ca/+ dep>tm5t ( ! ,van  ,wagn] %op1  
illu/rat$ 9 ,fig4 #ag1 !re are in/all$  
ab\t ?irty  ma*9es4 ,fig4 #bg %[s a     
die-ca/+ ma*9e 9 ! op5 position4  ,fig4 
#bf %[s a clos] view ( ! die-op]at+     
me*anism & ,fig4 #be  is pres5t$ to give
 a g5]al idea ( ! con/ruction ( ! entire
  ma*9e4    ,illu/ration3 ,fig4 #be4    
,draw+ illu/rat+ ,pr9ciple ( ,van ,wagn]
  ,die-ca/+ ,ma*9e    ,by ref]r+ to !   
l9e illu/ration ,fig4 #be1 :i* %[s !    
,van  ,wagn] pneumatic die-ca/+ ma*9e 9 
"p1 & comp>+ ?is  illu/ration ) ,fig4   
#bf1 :i* %[s ! g5]al appe>ance ( !      

die-op]at+ & o!r me*anism ( ! ca/+      
ma*9e1 a good idea  may be obta9$ ( its 
con/ruction & work+4 ,at ,a may be se5  
! base ( ! ma*9e 9 :i* is locat$ ! melt+
 pot ,b4 ,?is  melt+ pot is heat$ by    
means ( fuel oil pass+ ?r\gh ! supply   
pipe ,c to ! burn]s ,c#a4 ,a v5t pipe ,d
 is provid$ to take  away ! gases       
incid5t to combu/ion4 ,! pressure =     
8%oot+0 !  metal into ! die cavity is   
suppli$ by air ?r\gh ! supply pipe  ,e4 
,a valve controls ?is air supply4 ,!    
pressure is regulat$ to  suit ! p>ticul>
 ca/+ or die1 ! prop] am\nt be+ det]m9$ 
by exp]im5t4 ,simil>ly1 an air exhau/   
pipe ,f1 :i* may be se5  directly above 
! supply pipe1 sub-divides into two     
tubes :i*  ext5d to ! die cavity to     
exhau/ ! air be=e ! metal is  admitt$4  
,!re are two me?ods ( ov]com+ ! pres5ce 
( air 9  ! die cavity--! exhau/ me?od & 
! v5t+ me?od1 & x is  ! =m] t is "h     
describ$4    ,illu/ration3 ,fig4 #bf4   
,view ( ,ma*9e %[+ ,die-op]at+ ,me*anism
    ,a 8goose-neck0 ,g1 %[n 9 ,fig4 #be1

 s]ves to tempor>ily conta9  ! metal :i*
 is =c$ into ! mold4 ,an am\nt ( metal  
slightly  9 excess ( t requir$ = "o     
die-ca/+ is plac$ 9 ?is  goose-neck ) a 
h&-ladle1 previ\s to ea* op]ation ( !   
ma*9e4 ,"o end ( ! goose-neck is        
connect$ to ! air pipe1 ,e1  :ile ! o!r 
end t]m9ates 9 ! nozzle ,g#a4 ,?is      
nozzle may  be/ be se5 by ref]r+ to !   
illu/ration ( ! ma*9e %[n 9  ,fig4 #bg1 
9 connection ) ,fig4 #be4 ,"o ( !       
advantages 9 us+  ?is goose-neck is t ! 
entire air pressure is exp5d$ ^u !      
metal 9 ! goose-neck1 &1 by reason ( its
 isolat$ position1 !  goose-neck & its  
cont5ts are kept slightly hott] ?an !   
cont5ts  ( ! melt+ pot4      ,!         
,die-op]at+ ,me*anism    ,! die-op]at+  
me*anism ( ! ma*9e is conta9$ )9 a h+$  
framework1 %[n 9 position = ! removal ( 
! die-ca/+ 9 ,fig4  #bg4 ,ref]r+ to     
,fig4 #bf1 9 connection ) ! l9e         
illu/ration ,fig4  #be1 x w be se5 t !  
die-hold+ me*anism is all support$  ^u !
 l[] die-hold+ plate ,h1 :i* is h+$ to !

 edge  ( ! base ( ! ma*9e4 ,a lock ,j   
s]ves to hold ! dies &  op]at+ me*anism 
9 ! upright op]at+ position1 & by means 
( a c\nt]balance1 susp5d$ f an ov]head  
rope :i* connects  ) ! top ( ! me*anism 
at ,p1 ! *ang+ ( ! position (  ?is      
me*anism is easily effect$1 & :5 ?r[n   
into ! horizontal  position1 z indicat$ 
9 ,fig4 #bg1 x re/s ^u a support :ile ! 
dies are be+ op5$ & ! ca/+s eject$4     
,illu/ration3 ,fig4 #bg4 ,die-ca/+      
,ma*9e 9 ,position = ,removal (  ,ca/+  
,! l[] die is %[n at ,h#a & ! upp] die  
,k#a is m\nt$  ^u ! upp] die-hold+ plate
 ,k4 ,f\r rods ,l act z guid+  memb]s = 
! upp] die-hold+ plate to slide ^u4 ,^! 
rods ,l  are m\nt$ 9 fix$ positions at !
 corn]s ( ! l[] die-hold+  plate ,h1 &  
at _! upp] ends ! op]at+ %aft support+  
plate  ,m is locat$ 9 a fix$ position1  
s]v+ to support ! upp] ends  ( ^! rods4 
,! position ( ?is plate ,m is adju/able 
^u !  rods by means ( *eck-nuts1 ?us    
provid+ = ! accommodation (  ?ick z well
 z ?9 dies4 ,a %aft ,o is support$ 9 ?is

 top plate1  & by means ( ! op]at+ lev] 
,n work+ ?r\gh slott$ lev]s  ,o#a & l9ks
 ,o#b1 ! upp] die-hold+ plate & die c   
?us  be remov$ f contact ) ! l[] die at 
w4    ,! metal ent]s ! die cavity ?r\gh 
! nozzle ,g#a & aft]  sett+1 x is       
necess>y to cut ! sprue =m$ by ! surplus
 metal  t rema9s outside ! die cavity4  
,= ?is purpose1 a sprue-cutt]1  op]at$  
by means ( h&-lev] ,q#a1 is employ$4    
,?is sprue-cutt+  lev] is h+$ 9 !       
fulcrum$ l9k ,q#b1 & is held 9 its  ca/+
 position by means ( an adju/able /op on
 bracket ,q#c4    ,illu/ration3 ,fig4   
#bh4 ,g5]al ,view ( ,trimm+ ,dep>tm5t   
,9 _m dies1 x is necess>y t wat] be     
circulat$ ?r\gh !  die-blocks to keep !m
 cool dur+ ! die-ca/+ op]ation4 ,9      
,fig4 #bf1 ! wat] pipe may be se5 at ,r1
 & hose pipes run f  ?is supply to ea*  
side ( ! die-blocks1 ?us provid+ a cool+
  circulation4 ,9 ?is illu/ration1 !    
pipes us$ = exhau/+ !  air f ! die      
cavity are apt to be confus$ ) ! cool+  
pipes1  b by foll[+ ! two pipes lead+   

v]tically d[n to ! ma*9e1  ! exhau/     
pipes may be se5 & kept di/9ct f ! wat] 
pipes4      ,mak+ a ,die-ca/+    ,9 ord]
 to cle>ly und]/& ! op]ation ( !        
die-ca/+  ma*9e1 let u foll[ ! sequ5ce (
 ev5ts t takes place 9  produc+ a ca/+4 
,two m5 are requir$ to op]ate ! ma*9e4  
,9  ,fig4 #bg1 ! op]ators may be se5 9  
_! work+ positions4 ,!  fir/ /ep is tak5
 by ! op]ator at ! left :o1 ) a         
h&-ladle1  dips en\gh metal = "o ca/+ f 
! melt+ pot & p\rs x  ?r\gh nozzle ,g#a 
into ! goose-neck4 ,! second op]ator 9 !
  meantime is replac+ ! cores 9 ! dies1 
adju/+ ! position (  ! sprue-cutt] &    
clos+ ! dies prep>atory to mak+ a ca/+4 
,?is be+ done1 he elevates ! dies & _!  
op]at+ me*anism1  :i* are h+$ &         
c\nt]balanc$1 z previ\sly describ$1 br++
  !m to an upright position4 ,! die     
op]ator n[ m\nts ! box1  raises !       
sprue-cutt] to its op5 position to admit
 ! metal2 aft]  :i* ! ma*9e op]ator     
turns ! air valve ) 8 left h&4 ,!       
op]ation ( ?is air valve admits ! air   

beh9d ! metal1 =c+ x  into ! die1 & !   
same movem5t op5s ! exhau/ valve        
slightly 9  advance4 ,! exhau/ valve is 
locat$ ^u ! second l5g? ( pip+  j above 
! air valve1 & z a l9k connects ! two   
valves1 !  s+le motion exhau/s ! air f !
 die cavity & imm$iately  aft]w>d ! air 
is admitt$ beh9d ! metal1 !reby 8%oot+0 
!  metal into ! die4 ,?is be+ done1 !   
air is %ut (f & ! die  op]ator cuts !   
sprue by means ( lev] ,q#a1 )draws !    
cores  9 ! die1 ?r[s ! dies to ! op5    
position 7:i* is indicat$  9 ,fig4 #bg71
 & op]ates ! eject+ me*anism1 ?us remov+
 !  ca/+ f ! die4 ,9 ! meantime1 ! ma*9e
 op]ator is t5d+  to 8 metal supply &   
gett+ a ladle full ( metal ready = !    
next die-ca/+ op]ation4 ,by ref]r+ to ! 
ma*9es %[n 9 ,fig4  #ag1 x w be notic$ t
 only a few are provid$ ) exhau/ pip+  =
 v5t+ ! dies4 ,ano!r v5t+ me?od w be    
describ$ lat]4    ,illu/ration3 ,fig4   
#bi4 ,trimm+ ,die-ca/+s on a ,fil+      
,ma*9e    ,! numb] ( die-ca/+s :i* c be 
made on "o ma*9e p] day (  t5 h\rs v>ies

 ) ! "* ( ! pieces be+ die-ca/1 !  numb]
 ( pieces made at ea* op]ation ( ! ma*9e
 & ! ease  ) :i* ! dies may be work$1   
:i* dep5ds1 ( c\rse1 ^u !  numb] ( cores
 & p>ts to be h&l$ at ea* die-ca/+      
op]ation4  ,! dies %[n 9 ! ma*9e 9 ,fig4
 #bf1 produce f\r be>+s at ea*          
op]ation4      ,trimm+ ,die-ca/+s    ,at
 ! end ( ea* run ! op]ators ( ! ma*9es g
 ov] _!  "w1 break+ ! ca/+s f ! sprues &
 ?r[+ out all t  are defective4 ,no     
matt] h[ c>efully ! die-ca/+ molds h be5
  made1 !re is always a c]ta9 am\nt (   
trimm+ to be done on !  f9i%$ die-ca/+s1
 on acc\nt ( ! crevices left 9 ! die =  
air v5ts1 or :i* exi/ f improp] fitt+ ( 
! p>ts ( !  dies4 ,^! 8f9s10 z !y are   
call$1 are trimm$ by h& op]ators  9 a   
special dep>tm5t4 ,a g5]al view ( ?is   
trimm+ room is %[n  9 ,fig4 #bh4        
,usually x is suffici5t to scrape ^! f9s
 (f ) a  scrap+ knife1 b if ! ca/+ is   
especially difficult to produce1  s t a 
l>ge op5+ is requir$ to admit ! metal1 x
 is sometimes  necess>y to trim         

unusually ?ick sprue sections by fil+4  
,fig4 #bi  illu/rates ! me?od ( trimm+  
su* die-ca/+s on a fil+  ma*9e4         
,illu/ration3 ,fig4 #cj4 ,g5]al ,view ( 
,e4 ,b4 ,van ,wagn] ,co4's ,die  mak+   
,dep>tm5t    ,illu/ration3 ,fig4 #ca4 ,a
 ,typical ,die-ca/+ ,mold      ,! ,dies 
,us$    ,next to ! ca/+ ma*9e1 ! dies or
 molds are ! mo/ important  necess>y    
factor4 ,a g5]al view ( ! ,van ,wagn]   
,co4's die-mak+  dep>tm5t is %[n 9 ,fig4
 #cj4 ,9 ord] to ga9 a prop] conception 
(  ! "w requir$ 9 produc+ a high-grade  
die-ca/+ mold1 we w  foll[ ! diff]5t    
/eps :i* are necess>y 9 mak+ ! mold4 ,! 
fir/ & mo/ important /ep is ! prop]     
plann+ ( ! die4 ,be=e  any "w at all c  
be done1 x is necess>y to plan ! die1 i4
 e41  to decide j :]e ! p>t+ l9es w     
come2 j :at me?od  w be us$ = eject+ !  
piece2 :at alloy w be us$2 :]e  ! ca/+ w
 be gat$2 & a hundr$ & "o m9or po9ts1   
all (  :i* h a direct be>+ ^u ! p]=mance
 ( ! f9i%$ dies4  ,all ^! decisions h to
 be made by ! diemak]1 & 9 ,fig4 #cg he 

is %[n1 micromet] 9 h&1 comput+ !       
%r9kage all[ances t  he w make 9 ! dies4
 ,?is is a v important factor on        
accurate  "w z ! %r9kage v>ies f #j4jja 
to #j4jjd in*1 accord+ to !  alloy & !  
g5]al %ape ( ! piece4    ,illu/ration3  
,fig4 #cb4 ,die-ca/+ ,mold %[n 9 ,fig4  
#ca1 disassembl$    ,be=e tak+ up !     
actual ma*9+ op]ations ( ! mold-mak+  z 
conduct$ 9 ?is factory1 x w be well to  
take a typical  die-ca/+ mold & note its
 g5]al con/ruction4 ,fig4 #ca %[s a     
typical die-ca/+ mold clos$1 :ile ,fig4 
#cb %[s ! same mold  disassembl$ on !   
b5* to %[ its con/ruction4 ,! piece =   
:i* ! mold has be5 made is also %[n4    
,fig4 #cc %[s a simil>  die 9 section4  
,f ! ?ree illu/rations a good idea ( an 
av]age  die-ca/+ mold c be obta9$4      
,ref]r+ to ^! illu/rations1 !  pr9cipal 
p>ts ( ?is die are ! ejector box ,a1 & !
 ejector  plate ,b :i* is op]at$ by !   
racks ,c4 ,= op]at+ ! ejector  plate1 ! 
p9ion %aft ,d hav+ a h&le suitable =    
turn+1 is  furni%$4 ,?is1 ( c\rse1 fits 

into a bor$ hole 9 ! ejector box1  br++ 
! p9ion into me% ) ! racks = rais+ !    
ejector  plate4 ,9 ! ejector plate are  
?ree ejector p9s ,e = remov+  ! ca/+ f !
 mold4 ,! ejector p9s op]ate ?r\gh holes
 ,f4  ,beyond ! p9ion %aft may be se5 ! 
ca/+ = :i* ?is mold  has be5 made4 ,x w 
be notic$ t ! top side ( ! ca/+ has     
?ree project+ lugs ?r\gh :i* are small  
holes4 ,provision =  =m+ ?is side ( !   
die-ca/+ is made 9 ! l[] half ( !  mold 
,g1 :ile ! upp] half ( ! die-ca/+ is    
tak5 c>e (  by ! top plate ,h4 ,"o ( !  
toggles = op]at+ ! core p9s  ?r\gh ^!   
?ree lugs is %[n at ,i4 ,^! p>ts w be   
describ$  m fully lat]4 ,! sprue cutt]  
is %[n 9 position 9 ! die at  ,j4       
,ma*9+ ! ,die ,cavities    ,z w be      
notic$ f ,fig4 #cj1 ! ma*9]y 9 !        
die-mak+  dep>tm5t is ( mod]n design1 = 
no o!r class ( "w dem&s z  good tool    
equipm5t & z mu* skill 9 ! mak+ z       
die-ca/+  molds4 ,! die-blocks are made 
( ma*9]y /eel4 ,fig4 #cd illu/rates  !  
fir/ /ep 9 mak+ a die-ca/+ mold aft] !  

die-block has  be5 %ap$ approximately to
 size4 ,?is op]ation consi/s 9 c>efully 
fac+ (f ! die surfaces on a             
v]tical-sp9dle gr9d+ ma*9e4  ,?is1 (    
c\rse1 is a quick me?od ( surfac+ !     
die-block1 &  x insures t ! top & bottom
 surfaces ( ^! plates w be  p>allel1    
p]mitt+ ! die-faces to come toge!r      
prop]ly4    ,illu/ration3 ,fig4 #cc4    
,section ?r\gh a ,die-ca/+ ,mold    ,!  
next /ep consi/s ( lay+ out ! die1 z %[n
 9 ,fig4 #cf4 ,?is  is done 9 ! usual   
mann]1 by work+ on a copp]$ surface1 us+
  divid]s1 scales1 & a c5t] pun*4 ,:5   
lay+ out ! die1 !  necess>y all[ances   
are made = %r9kage & f9i%1 ^! po9ts     
hav+ be5 plann$ be=e actual "w on ! die 
has be5 />t$4 ,z  9 o!r phases ( die-"w1
 ! ma*9+ op]ations are p]=m$1  z f> z   
possible1 be=e any h&-"w is done4 ,9    
,fig4 #ch may be  se5 a die-mak] turn+ !
 cavity 9 a "p ( ! die-ca/+ mold4  ,!   
highe/ type ( skill$ workman%ip is call$
 = on ?is ma*9e  "w1 & z may be surmis$ 
f ,fig4 #ch1 :]e ! die-mak] is %[n      

measur+ ! die ) a v]ni] calip]1 !       
measurem5ts mu/ be  exact1 = no gr9d+   
op]ations foll[ ! ma*9e "w4             
,illu/ration3 ,fig4 #cd4 ,fir/ /ep 9    
mak+ ! ,mold--,gr9d+  ,surfaces (       
,blocks    ,illu/ration3 ,fig4 #ce4 ,a  
,mill+ ,op]ation on a ,die    ,figs4 #ce
 & #ci %[ typical mill+ op]ations be+   
p]=m$ on  die-ca/+ molds4 ,9 ,fig4 #ci !
 diemak] is %[n indicat+ a p9 9  "o     
corn] ( ! mold cavity1 prep>atory to do+
 additional mill+4  ,! block is held 9 !
 usual mann] by be+ clamp$ on ! b$ (  ! 
mill+ ma*9e1 & aft] x has be5 prop]ly   
locat$ "u !  cutt] head1 tools are      
sub/itut$ = ! indicator & ! mill+  ( !  
cavity is complet$4 ,fig4 #ce %[s "o ( !
 sections ( !  die-ca/+ mold :i* is to  
be us$ 9 produc+ ! ca/+ %[n at  ! "r ( !
 "w4 ,9 ?is case ! diemak] is mill+ !   
recess  = ! /eel arbor :i* may be se5   
directly 9 ! =egr\nd4 ,?is  w be fitt$ 9
 place to provide = ! =m+ ( ! hole 9 !  
side ( ! piece4    ,illu/ration3 ,fig4  
#cf4 ,lay+ out ,"o ( ! ,mold ,p>ts      

,illu/ration3 ,fig4 #cg4 ,plann+ !      
,die-ca/+ ,mold    ,illu/ration3 ,fig4  
#ch4 ,turn+ out a ,die-ca/+ ,mold       
,illu/ration3 ,fig4 #ci4 ,indicat+ a    
,mold on ! ,mill+ ,ma*9e    ,fig4 #dj   
illu/rates sev]al important po9ts 9 !   
mak+ ( a  die-ca/+ mold4 ,?is           
illu/ration %[s ! ejector box ) !  l[]  
half ( ! mold on x1 ! ejector plate be+ 
held aga9/ !  "u side ( ! die-plate by  
means ( ! p9ion %aft4 ,! op]ation  be+  
done is ! drill+ ( ! ejector-p9 holes4  
,ref]r+ back to  ,fig4 #cb1 :i* by ! way
 %[s ! die "h illu/rat$ disassembl$1  ! 
holes be+ drill$ are ^? %[n at ,f = !   
reception ( !  p9s ,e4 ,! me?od employ$ 
is to drill ! holes ?r\gh ! die &  into 
! ejector plate1 aft]w>d ream+ all holes
 to size & driv+  ! p9s into position 9 
! ejector plate1 :ile !y are all[$ to   
slide freely ?r\gh ! die-plate4 ,we w n[
 assume t ! ejector  box & plate h be5  
complet$ & fitt$1 a p9ion %aft =  op]at+
 ?is plate also fitt$1 ! l[] & upp] dies
 complet$  by ! ma*9+ op]ations         

previ\sly describ$1 & all assembl$4  ,! 
f9al op]ation ( ! fitt+ ( ! p9s is %[n 9
 ,fig4 #da 9  :i* ! die-mak] may be se5 
fil+ (f ! ends ( ^! p9s s  t :5 dropp$  
to ! l[] position !y w lie flu% ) !     
surface4 ,if ( unev5 l5g?s1 ^! p9s w    
cause irregul> spots 9  ! ca/+4 ,x n[   
rema9s to describe ! toggles us$ =      
op]at+  ! cores :i* =m ! holes ?r\gh !  
?ree lugs 9 ! ca/+4  ,"o ( ^! toggles1 (
 :i* !re are ?ree1 is %[n at ,i1 9      
,fig4 #ca1 & also 9 ,fig4 #cb4 ,^!      
toggles consi/ ( brackets :i*  are      
atta*$ to ! die-plate1 & lev]s :i* are  
fulcrum$ at !  ends ( ! brackets s t _! 
op]ation works ! core p9s4 ,x is        
necess>y to remove ^! core p9s aft] ea* 
ca/+ has be5 made  & position !m be=e   
ano!r ca/+ c be produc$4                
,illu/ration3 ,fig4 #dj4 ,drill+ !      
,ejector-p9 ,holes    ,! fitt+ ( ! p>ts 
( a die-ca/+ mold is "o ( !  mo/        
important p>ts ( ! "w4 ,x dem&s ! highe/
 type (  workman%ip1 = a poorly fitt$   
die means a die :i* works h>d  9        

addition to produc+ poor ca/+s4 ,x is v 
important t  all movable p>ts %\ld "w   
freely4 ,fig4 #db %[s ! assembl+        
op]ation on a die-ca/+ mold1 ! ca/+ :i* 
is to be duplicat$  be+ %[n 9 ! imm$iate
 =egr\nd4 ,^! p>ts mu/ all be  screw$   
into _! respective places1 mak+ ! jo9ts 
z ne>ly  air-tight z possible4 ,"o cause
 ( poor die-ca/+s arises f !  trapp+ (  
air 9 ! die1 & diff]5t me?ods are       
employ$ =  ov]com+ ?is tr\ble4          
,v5t+ ! ,dies    ,!re are two me?ods (  
prev5t+ air f be+ trapp$ 9  die-ca/+    
molds2 ei!r by con/ruct+ ! dies s t !   
air  may be exhau/$ f ! mold cavity be=e
 admitt+ ! metal1 or  by v5t+ ! die s t 
! air may be =c$ out by ! inru%+  metal4
 ,9 ! fir/ ( ^! me?ods x is necess>y t !
 jo9ts 9  ! mold be made z close z      
possible1 o!rwise x w be impossible  to 
produce any?+ l a vacuum 9 ! mold       
cavity4 ,if1 h[ev]1 x  has _m p>ts :i*  
mu/ be fitt$1 x is usually consid]$     
advisable  to provide ! die ) v5ts      
consi/+ ( mill$ recesses a few  ?\s&?s  

in* deep4 ,sev]al v5ts are provid$1 f   
:i* ! air  c escape :5 ! metal is       
admitt$ to ! dies4 ,! hot metal1 (      
c\rse1 8%oots0 ?r\gh !m 9 ?9 ribbons1 b 
n en\gh escapes  to affect ! pressure on
 ! metal :i* goes into ! ca/+4          
,illu/ration3 ,fig4 #da4 ,fitt+         
,ejector-p9s    ,no matt] h[ c>efully a 
die may h be5 con/ruct$1 or h[  c>efully
 x has be5 assembl$1 !re is always a    
c]ta9 am\nt (  8baby+0 to be done be=e x
 w "w satisfactorily4 ,! ca/+  may /ick 
a little "h1 or !re may be a r\gh spot  
!re1 & x  is ! successful elim9ation (  
^! tr\bles :i* con/itutes !  production 
( a good die-ca/+4      ,die-ca/+       
,metals    ,"o ( ! purposes ( ?is book  
is to correct sev]al errone\s           
impressions :i* are preval5t 9 reg>d to 
die-ca/+ possibilities4  ,_m p seem to  
?9k t ne>ly all metals c be die-ca/1 b  
z a matt] ( fact1 ^? metals :i* c be    
successfully die-ca/  c be numb]$ on !  
f+]s ( "o h&1 be+ alloys ( lead1 z9c1   
t91 copp] & antimony4 ,! t9 base metals 

%r9k v little1 :ile  ! z9c base metals  
%r9k consid]ably1 & ^? ) a l>ge p]  c5t 
( alum9um h a v high %r9kage4 ,)\t d\bt1
 ! mo/  us$ die-ca/+ metals are ! z9c   
base metals4 ,a typical metal (  ?is    
class conta9s ab\t #he p] c5t z9c2 #h p]
 c5t t92 #d p]  c5t copp] & #c p] c5t   
alum9um4 ,! melt+ po9t ( ?is metal  is  
ab\t #hej degrees ,f4 ,:ile ?is alloy is
 "o ( ! mo/ common1  x is n by any means
 ! be/1 z !re is too little t9 employ$1 
b x is a comp>atively *eap metal1 :i*   
probably acc\nts = its  l>ge use4 ,?is  
metal is easily affect$ by heat & cold1 
& rapidly  det]iorates ) age4 ,! lead   
base metals may be typifi$ by an alloy  
conta9+ #hj p] c5t lead2 #ae p] c5t     
antimony2 #d p] c5t t92 &  #a p] c5t    
copp]4 ,?is composition melts at        
approximately #eej degrees  ,f4 & is us$
 = ca/+s subject$ to little we> & :]e no
  great /r5g? is requir$4 ,! weight (   
?is metal is its greate/  objection1 & x
 is also q brittle because ( ! l>ge     
p]c5tage  ( antimony4    ,illu/ration3  

,fig4 #db4 ,assembl+ a ,die-ca/+ ,mold  
,= ! be/ class ( die-ca/+s1 ! t9 base   
metals are employ$4  ,^! range f #fj to 
#ij p] c5t t91 & f #b to #aj p] c5t     
copp]1 toge!r ) a little antimony4 ,!   
melt+ po9t ( a  mixture ( ?is           
composition is ab\t #fge degrees ,f4 ,! 
ca/+s h  a good color & !y are mu* bett]
 9 quality ?an any ( ! o!r  alloys4 ,x  
is absolutely ess5tial t t9 base metals 
be us$ =  c>buret] p>ts or o!r p>ts com+
 9 contact ) gasol9e4 ,also1  ! t9 base 
metals mu/ be us$ = p>ts :i* come 9     
contact )  food products1 z ! lead or   
z9c alloys h a contam9at+ effect4       
,alum9um alloys h be5 ca/ 9 ,france &   
,g]many 9 limit$  quantities1 b v seldom
 9 ?is c\ntry on acc\nt ( _! high  melt+
 po9t1 z well z _! effect ^u ! die4     
,aft] alum9um  alloys h be5 run 9 ! dies
 = a %ort "t1 ! surfaces ( !  molds     
become pitt$4 ,?r\gh "s unexpla9$ cause1
 ! metal seems  to flake out p>ticles ( 
! /eel 9 ! molds4 ,:5 an alum9um  alloy 
is to be us$1 a good mixture is #hj p]  

c5t alum9um1 #c p] c5t  copp] & #ag p]  
c5t z9c4 ,?is alloy has a high %r9kage &
 x has  also ! same det]iorat+ effect ^u
 ! dies1 b to a mu* less  degree ?an    
pure alum9um4          ,transcrib]'s    
,notes      ,punctuation1 hyph5ation1 & 
spell+ 7 made consi/5t :5 a  pr$om9ant  
pref]5ce 0 f\nd 9 ?is book2 o!rwise !y 7
 n  *ang$4    ,simple typographical     
errors 7 correct$2 occasional unbalanc$ 
quotation m>ks reta9$4    ,ambigu\s     
hyph5s at ! ends ( l9es 7 reta9$4       
,text uses 8die-cavity0 & 8die cavity01 
8die-mak]0 & 8die mak]02  none *ang$ "h4