DIE CASTINGAluminum · Zinc · Dies · Machining · Finishing
High pressure die casting
Custom die castings made from your drawing
In high pressure die casting, molten aluminum or zinc is injected into a hardened steel die at high speed and then held under intensification pressure while it solidifies. The cavity fills in a few hundredths of a second (typical) and the casting is ejected seconds later. You get a near-net-shape part with thin walls, cast-in holes and a surface that needs work only where it is machined or finished. The process pays off at annual volumes from a few thousand to several hundred thousand parts (typical).
We supply aluminum and zinc die castings to your drawing, with the die, trimming, CNC machining and surface finishing.
Cold chamber and hot chamber die casting
| Cold chamber | Hot chamber | |
|---|---|---|
| How metal is fed | Ladled, by hand or by an automatic ladle, from a holding furnace into the shot sleeve for every shot | The gooseneck and plunger sit in the molten metal pot; each stroke pushes metal into the die |
| Why | Molten aluminum attacks iron and steel, so the injection system cannot stay in the melt | Zinc melts at about 385 °C, low enough for a submerged injection system |
| Typical alloys | Aluminum (A380, ADC12), larger magnesium parts, brass | Zinc (Zamak 3, 5, 2), small magnesium parts |
| Cycle | Longer, ladling adds time to each shot | Shorter, small zinc parts often run several shots a minute |
| Typical parts | Housings, heat sinks, brackets, structural parts | Small precise parts, hardware, decorative parts |
Typical, simplified comparison.
Housings, heat sinks, enclosures and brackets in A380, ADC12 and A360.
Zamak 3 and Zamak 5 die castings: fine detail, thin walls, ready for plating.
When magnesium makes sense, how it compares with aluminum, and what it requires.
Gravity (permanent mold) and sand castings for heat-treated, thicker or lower-volume parts.
Die casting FAQ
What is high pressure die casting?
Molten metal, usually aluminum or zinc, is injected into a hardened steel die at high speed and held under pressure while it solidifies. It gives complex, thin-walled parts with consistent dimensions. Typical cycle times run from a few seconds for small zinc parts to a minute or more for large aluminum housings.
When is die casting the right process?
When the part has thin walls and a complex shape and the volume is high enough to pay for a steel die, typically several thousand parts a year or more. Below that, gravity or sand casting, or machining from solid, often costs less overall.
What do you need to quote a die casting?
A 3D model (STEP or IGES), a 2D drawing with tolerances, the alloy or required properties, the annual volume, and any machining, finishing, leak-tightness or X-ray requirements.
Do you supply the die and the castings?
Yes. We design and build the die, run the trials and supply castings trimmed, machined and finished as your drawing requires. Die ownership is stated in the quotation.