This thesis presents the development of the DFMEA method for the R&D, design, and manufacturing of high-pressure casting molds for aluminum products for the automotive industry. The introduction chapter, which defines the discussed issue and objectives of the thesis, is followed by a detailed presentation of the mold construction and its operation and also explains the operation of all systems that are a part of the tool and that enable high-quality casting. Furthermore, the thesis presents the entire process of development, design, and manufacturing of the die-casting mold in the tool shop. The methodological part of the thesis presents the FMEA method, which we used to develop the DFMEA for the die-casting mold and that contains guidelines for designing an optimal and robust mold design to prevent the occurrence of failures and achieve the mold’s primary functions. The fourth chapter of the thesis presents step-by-step the implementation and results of the DFMEA methodology used for the high-pressure die-casting mold. Using the DFMEA method, we will be able to identify and evaluate specific weak areas of the design and construction of new or existing molds for each project. With the help of the lessons learned and reclamation reports, we will be able to optimize the mold design, which directly affects the casting quality and the reliability of the molds.
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