Die Casting
High-Volume Aluminum, Zinc & Magnesium Casting
Die casting delivers tight-tolerance, high-volume non-ferrous components with excellent surface finish and dimensional repeatability.
Process Overview
When to use die casting
Die casting forces molten metal into hardened steel dies under high pressure, producing components with precise dimensions, good surface finish, and fast cycle times. It is the most economical process for high-volume production of aluminum, zinc, and magnesium components.
Die casting is well-suited for enclosures, housings, heat sinks, automotive components, and other parts where volume, consistency, and cost efficiency matter. Tooling investment is higher than sand casting but per-piece cost drops significantly at volume.
Typical Volume
Medium to high (5,000 – 500,000+ pcs/year)
Best For
- High production volumes
- Aluminum and zinc alloys
- Thin walls and fine detail
- Near-net-shape with minimal post-machining
- Cost-sensitive production programs
Process Strengths
- Fastest cycle times for high-volume runs
- Excellent dimensional repeatability
- Good surface finish as-cast
- Lower per-piece cost at volume
- Suitable for complex thin-wall parts
Common Materials
- Aluminum alloys (A380, A383, ADC12)
- Zinc alloys (Zamak 3, 5)
- Magnesium alloys (AZ91D)
Typical Components
- Automotive housings and covers
- Enclosures and brackets
- Transmission and engine components
- Consumer and industrial hardware
- Heat sinks and thermal components
Secondary Services
- Trimming and deburring
- CNC machining
- Anodizing and painting
- Pressure leak testing
- Sub-assembly
Related
Related materials, industries & products
Related Industries
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