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And the engineered safety factor is roughly 2. Introducing a world first The result? The innovators at Calgary-based SigmaDek knew there had to be a better way and approached Dynacast to help them find it. The issue was designing components whose strength did not come at the expense of economical casting or feature integration. For example, thicker wall sections or ribs might make it easier to meet structural requirements but they also add to the cost to the casting process. Properly maintained, a deck is an extension of your living space and an asset to any property. As a result, the all-aluminum deck system must undergo rigorous testing, which is ongoing. For example, the connector between joist and stair stringer had to withstand stresses of 15, psi. We spent some time with Brian Boettger, VP Product Development to find out more. Putting safety first One of the challenges the team faced was that The International Building Code had no provisions for aluminum components in decks. Year-in, year-out, wooden decks demand regular maintenance—from resurfacing to varnishing. Changes included the elimination of undercuts, the addition of draft angles to some features, wall thicknesses, structural ribs, gates, runners, and overflows. But as any deck owner knows: they can be a lot of work. From idea to design However, in order to manufacture the precision components SigmaDek required, they needed die casting expertise which is when they turned to Dynacast. Strong, sustainable and designed to enhance the beauty of any home, SigmaDek is the result of the finest minds in die casting and decking working together to achieve a world first.{/INSERTKEYS}{/PARAGRAPH} Of course, until now, wood has always been the default material used for decks. By making the parts easier to die cast, the DFM modifications produced a significant cost benefit. Stresses of that magnitude are within the capabilities of die cast aluminum. {PARAGRAPH}{INSERTKEYS}アルミニウム 設計 ダイカスト DFM For Aluminum Die Castings When you think of an outdoor deck, the first thing you think of is probably wood. But not any longer if SigmaDek has anything to do with it. Savings came in the form of less complex tooling, faster cycle times, and fewer secondary machining operations. We identified Dynacast as that partner and reached out to them very early on.