High-Pressure Die Casting

The definitive solution for manufacturing complex metal parts at scale. We leverage die casting to produce thousands of strong, lightweight, and dimensionally accurate components.

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A complex metal impeller, a typical application for die casting

The Process: Forcing Molten Metal into a Mold

High-pressure die casting is a manufacturing process where molten metal is forced into a hardened steel mold (called a die or tool) under immense pressure. The process is similar to plastic injection molding but uses non-ferrous metal alloys like aluminum and zinc.

The molten metal solidifies rapidly inside the cool die. Once solid, the die opens and the part, called a "casting," is ejected. This process can be highly automated and has very fast cycle times, making it an extremely cost-effective method for producing metal parts in high volumes.

A steel mold blank, similar to the dies used in die casting

Why Choose Die Casting?

Complex Geometries

Die casting excels at producing complex, net-shape parts with thin walls, intricate features, and excellent dimensional accuracy, often requiring minimal secondary machining.

Excellent Surface Finish

Parts produced via die casting have a very smooth surface finish as-cast, which can be further improved with post-processing like bead blasting, polishing, or painting.

Low Per-Part Cost at Scale

While the initial tooling investment is significant, the fast cycle times and automation lead to a very low piece-part price, making it ideal for high-volume production.

Common Die Casting Alloys

Aluminum Alloys (e.g., A380)

Aluminum is the most common die casting material. It offers an excellent combination of light weight, good strength, high operating temperatures, and corrosion resistance. It is used extensively in automotive, electronics, and industrial applications.

Zinc Alloys (e.g., Zamak 3, 5)

Zinc alloys are easier to cast than aluminum, have a lower melting point (leading to much longer tool life), and can produce parts with even thinner walls and better surface finish. They are excellent for decorative hardware, housings, and components requiring high ductility.

Die Casting FAQ

How does die casting compare to CNC machining?

Die casting is a forming process, while CNC machining is a subtractive one. For high volumes (typically 5,000+ parts), die casting has a much lower per-part cost but a very high initial tooling cost. CNC machining has no tooling cost, making it ideal for prototypes and low volumes, but a much higher per-part cost that doesn't decrease significantly with volume.

What are the design rules for die casting?

Die casting design rules are very similar to injection molding. Key principles include maintaining uniform wall thickness, adding generous draft angles (typically 2 degrees or more), using fillets and radii on all corners, and avoiding undercuts where possible.

Can you put threads in a die cast part?

Yes. External threads can often be cast directly into the part. Internal threads are typically created in a secondary operation after casting, either by tapping (cutting threads) or by roll forming (forming threads), which is stronger. Threaded inserts can also be used.