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Manufacturing Process

Die Casting Services

High-pressure die casting combined with precision CNC machining for complex, high-volume parts. Excellent dimensional accuracy, smooth surfaces, and cost-effective production.

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Benefits

Why Die Casting?

Die casting offers unique advantages for producing complex metal parts at scale.

High Production Speed

Cycle times as fast as 15-60 seconds per part. Ideal for high-volume production runs of 10,000+ parts.

Dimensional Accuracy

Tolerances as tight as ±0.002" per inch achievable as-cast. Minimal machining required.

Complex Geometries

Produce intricate shapes with thin walls, undercuts, and internal features in a single operation.

Excellent Surface Finish

As-cast surface finish of 63-125 Ra microinches. Ready for plating, painting, or powder coating.

Material Efficiency

Near-net-shape production minimizes waste. Scrap material is 100% recyclable.

Cost Effective

Low per-part cost at volume. Amortized tooling cost decreases with quantity.

Materials

Die Casting Alloys

We work with a range of die casting alloys optimized for different applications.

Aluminum Die Casting

Most popular choice for lightweight, strong components

Common Alloys:

A380, A383, A360, ADC12, AlSi9Cu3, AlSi12

Properties:

  • Excellent strength-to-weight ratio
  • Good corrosion resistance
  • High thermal conductivity
  • EMI/RFI shielding capability

Applications:

Automotive housings, heat sinks, enclosures, structural components

Zinc Die Casting

Best surface finish and finest detail reproduction

Common Alloys:

Zamak 3, Zamak 5, Zamak 7, ZA-8, ZA-12, ZA-27

Properties:

  • Superior castability and detail
  • Excellent surface finish
  • High impact strength
  • Long die life (up to 1M shots)

Applications:

Hardware, connectors, decorative parts, precision components

Magnesium Die Casting

Lightest structural metal for weight-critical applications

Common Alloys:

AZ91D, AM60B, AM50A, AE44

Properties:

  • 33% lighter than aluminum
  • Excellent machinability
  • Good damping characteristics
  • EMI shielding properties

Applications:

Electronics housings, automotive parts, aerospace components

Capabilities

Die Casting Process

State-of-the-art equipment and processes for consistent, high-quality parts.

01

Hot Chamber

For zinc and magnesium alloys. Faster cycle times, lower operating temperatures. Ideal for small to medium parts.

Machines: 150-800 ton
02

Cold Chamber

For aluminum and brass alloys. Higher pressures, better for larger parts and alloys with higher melting points.

Machines: 400-2500 ton
03

CNC Machining

Secondary operations for tight tolerances, threaded holes, and precision surfaces not achievable as-cast.

Tolerances: ±0.0005"
04

Finishing

Complete finishing options including deburring, tumbling, plating, anodizing, powder coating, and painting.

Surface: Ra 32-125 μin
Specifications

Technical Capabilities

Part Size

Aluminum Up to 30 kg
Zinc Up to 5 kg
Magnesium Up to 10 kg

Tolerances

As-Cast Linear ±0.002"/inch
CNC Machined ±0.0005"
Draft Angle 1-3°

Wall Thickness

Aluminum Min 1.5mm (0.060")
Zinc Min 0.75mm (0.030")
Magnesium Min 1.0mm (0.040")
Industries

Applications

Die cast components serve diverse industries with demanding requirements.

Automotive

Transmission cases, engine blocks, brackets, heat sinks, lighting housings

Electronics

Enclosures, heat sinks, connectors, EMI shielding, laptop frames

HVAC

Compressor housings, fan blades, valve bodies, heat exchangers

Lighting

LED housings, street light fixtures, decorative lighting components

Power Tools

Motor housings, gear cases, handles, structural components

Hardware

Locks, handles, hinges, furniture fittings, decorative hardware

Start Your Die Casting Project

From prototype tooling to high-volume production, our team can help you optimize your die cast design for manufacturability and cost.