Contents
Manufacturing Insight: Die Casting Service
Precision Metal Components Through Integrated Die Casting and CNC Machining
Honyo Prototype delivers end-to-end manufacturing solutions for complex metal components, combining high-integrity die casting with precision CNC machining to meet stringent engineering requirements. Our die casting services produce near-net-shape aluminum, zinc, and magnesium parts with exceptional dimensional stability and surface finish, while our in-house CNC machining capabilities ensure critical features achieve tight tolerances unattainable through casting alone. This integrated approach eliminates supply chain fragmentation, reduces lead times by up to 30%, and guarantees seamless transition from raw casting to fully finished, assembly-ready components.
Engineers and procurement teams leverage our proprietary Online Instant Quote platform to receive accurate, real-time cost and lead time estimates for both die casting and secondary CNC operations within minutes. Upload CAD files to instantly evaluate manufacturability, material options, and process synergies—accelerating prototyping and low-volume production without compromising on quality or precision.
Material and Process Capabilities Summary
| Process | Materials Supported | Tolerance Range | Max Part Weight | Key Applications |
|——————|—————————|—————–|—————–|——————————–|
| Die Casting | A380, ADC12, Zamak 3, AZ91D | ±0.1 mm | 10 kg | Enclosures, brackets, housings |
| CNC Machining | All cast alloys + steel, brass | ±0.025 mm | 50 kg | Critical interfaces, threads, seals |
By unifying die casting and CNC under one quality-controlled workflow, Honyo Prototype ensures repeatability for mission-critical components across automotive, medical, and industrial sectors. Start your project with a validated quote today—no RFQ delays, no estimation gaps.
Technical Capabilities
Die casting is a high-pressure metal casting process suitable for producing complex, high-integrity metal parts in large volumes. When paired with precision secondary operations such as 3, 4, and 5-axis CNC milling and turning, die cast components can achieve tight tolerances and superior surface finishes required in aerospace, automotive, and medical industries. These machining operations are essential for achieving critical feature accuracy on die cast parts that cannot be attained directly from the casting process.
The combination of die casting with multi-axis CNC machining allows for precise feature alignment, complex geometries, and tight tolerance control typically within ±0.005 mm (±0.0002″) for critical dimensions, depending on part size and material. Surface finishes can reach up to 32 µin (0.8 µm) Ra when required.
Common materials used in die casting and subsequent precision machining include Aluminum alloys (e.g., A380, A360, ADC12) for lightweight and high-strength applications. Steel is typically not die cast due to high melting point and viscosity but may be used in tooling or for hybrid assemblies. For non-metallic components, ABS and Nylon are processed via injection molding rather than die casting but are often machined using the same 3–5-axis platforms for prototyping or low-volume production.
Below is a summary of technical specifications for die casting services enhanced with precision CNC machining:
| Feature | Specification |
|---|---|
| Primary Process | High-pressure die casting (HPDC) |
| Secondary Machining | 3-axis, 4-axis, and 5-axis CNC milling, CNC turning |
| Typical Tolerances | ±0.025 mm (±0.001″) standard; tight tolerances down to ±0.005 mm (±0.0002″) |
| Surface Finish (Machined) | 32–64 µin (0.8–1.6 µm) Ra, customizable with polishing or coating options |
| Maximum Part Size (Milling) | Up to 1200 x 800 x 600 mm (47″ x 31″ x 24″) depending on machine envelope |
| Minimum Wall Thickness | 0.8–3.0 mm (0.03–0.12″), depending on alloy and geometry |
| Materials – Die Casting | Aluminum (A380, A360, ADC12, A356), Zinc alloys |
| Materials – Machining | Aluminum, Steel (for inserts or hybrid parts), ABS, Nylon (via CNC, not cast) |
| Lead Time (Prototype) | 15–25 days including casting, machining, and inspection |
| Quality Standards | ISO 9001:2015, PPAP, First Article Inspection (FAI), CMM reporting |
Note: ABS and Nylon are not suitable for die casting due to thermal and pressure limitations of the process. These polymers are instead processed via injection molding or CNC machining from stock. However, they are included here as commonly requested materials in prototyping services that complement die cast metal components in final assemblies.
From CAD to Part: The Process
Honyo Prototype Die Casting Service Workflow
Honyo Prototype executes die casting projects through a rigorously structured, technology-enabled workflow designed for precision, speed, and manufacturability. The process begins with CAD Upload, where clients submit 3D models in industry-standard formats (STEP, IGES, Parasolid). Our integrated platform performs immediate geometry validation, checking for critical parameters like wall thickness uniformity, draft angles, and undercuts. Invalid submissions trigger automated feedback specifying required corrections, minimizing iterative delays.
The validated CAD model progresses to AI-Powered Quoting. Our proprietary algorithm analyzes geometric complexity, material requirements (aluminum ADC12/A380, zinc ZAMAK 3/5, magnesium AZ91D), part volume, and surface finish specifications. The system cross-references real-time data on tooling costs, material pricing, machine availability, and labor rates to generate a comprehensive quote within 2 hours. This includes itemized cost breakdowns for tooling, unit production, secondary operations, and expedited shipping options, with clear lead time projections based on current production capacity.
Following client acceptance, the DFM (Design for Manufacturability) Review phase commences. Honyo’s senior manufacturing engineers conduct a collaborative analysis, not merely an automated check. Key focus areas include:
| DFM Parameter | Analysis Criteria | Typical Resolution Path |
|---|---|---|
| Wall Thickness | Minimum 1.5mm (aluminum), avoidance of abrupt transitions | Recommend uniform sections or localized ribbing |
| Draft Angles | Minimum 1° per side for ejection | Suggest incremental increases for deep cavities |
| Parting Line Placement | Minimize undercuts, optimize ejection force | Propose alternative orientations |
| Gate & Runner Design | Flow simulation for air entrapment reduction | Redesign injection points iteratively |
Engineers provide marked-up CAD revisions with technical rationale, requiring client concurrence before tooling fabrication. This phase typically reduces production defects by 35–50% and avoids costly mid-process redesigns.
Production initiates upon DFM approval. Honyo utilizes 150–2,500 ton cold-chamber die casting machines (Buhler, Toshiba) under ISO 9001-controlled conditions. Each run includes:
First-article inspection per ASME Y14.5 with CMM reports
In-process SPC monitoring of critical dimensions (±0.05mm typical)
Real-time metal chemistry verification via spectrometry
Post-casting T6 heat treatment (for aluminum) and precision trimming
Secondary operations like CNC machining, anodizing, or powder coating occur in-house with strict chain-of-custody tracking.
Delivery encompasses final quality documentation and logistics. All shipments include:
Dimensional inspection reports (FAIR)
Material test certificates (MTRs)
Process validation records (including pressure curves)
Parts are packaged in ESD-safe, anti-corrosion containers with custom foam inserts, shipped via DHL/FedEx with real-time supply chain visibility. Standard lead time from CAD upload to delivery is 18–25 days for aluminum tooling and first production units, with expedited options available. This integrated workflow ensures technical feasibility is validated before commitment, aligning client expectations with executable manufacturing outcomes.
Start Your Project
Looking for high-quality die casting services? Partner with Honyo Prototype for precision manufacturing and reliable production. Our state-of-the-art facility in Shenzhen supports efficient, scalable die casting solutions for demanding industries.
Contact Susan Leo today at [email protected] to discuss your project requirements and receive a personalized quote.
🚀 Rapid Prototyping Estimator
Estimate rough cost index based on volume.