If you have to design a particular part for mass production, then you have a number of different ways to approach the task from an engineering perspective. You will need to take into account a number of different criteria as you narrow down your chosen process and while some people may have told you that die casting is the way to go, how does this compare with other solutions?
Die Casting Superiority
Die casting is generally accepted to be the most economical and efficient process for a job like this. You can produce a number of complex shapes to a relatively close tolerance with very little machining work, and thousands of identical examples can be produced at high speed. Each of these parts will be heat-resistant, and you can rely on the process to turn out stable and durable parts throughout the production run.
Plastic Injection Moulding
But what about plastic injection moulding? This approach may be cheaper when you compare the solution on a unit by unit basis, but the die cast version will be much stiffer and stronger. You won't need to worry about weathering or sensitivity to other chemicals or agents either.
You can eliminate the forging process from your thoughts as well, as die casting is able to cope with a much more complex design while allowing you to work with thinner sections. Your approach may simply not be feasible for a forge.
The same philosophy may apply to the stamping machine, as you can certainly make a product that is far more intricate when you choose die casting. A stamping machine can turn out simpler forms in less time, but this approach is not likely to help you achieve your objectives.
The Best Approach
Make a list of the important criteria before you finally decide on the way forward. While you can choose an intricate design, try to keep each section as uniform as possible to make it easier to avoid any complications. Where possible, you should also avoid the need for machining, but if this is inevitable, make sure that you have enough metal to allow for the required cuts.
Getting Expert Confirmation
Talk with your machining expert before you finally make your choice. They will be to advise you of any other design criteria and confirm that you are taking the right approach for your project.