Custom Die Casting Services
- We deliver precision die casting solutions with high output, tight tolerances, and smooth surface finishes.
- Our efficient, high-speed processes minimize machining, shorten lead times, and deliver complex, cost-effective parts tailored to diverse industries and custom specifications.
- ±0.1 mm Dimensional Accuracy
- Thin Walls Down to 0.75 Mm
- Casts Complex Shapes with Sleeves and Inserts
- Tensile Strength Reaches 415 MPa
- Cuts Finishing Time by 60%
- Reduces Cost by 25–45% in High Volumes
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Common Steps of Die Casting
Die casting is a process used in manufacturing to form precise, complex metal components. Below are the standard steps involved:
Design and Mold Creation
Engineers use CAD software to design parts and create strong steel molds that meet exact specs for consistent casting results.
Mold Heating
Preheat molds to optimal temperatures to prevent shock and ensure smooth metal flow and quality surface finish.
Metal Melting
Melt metal alloys in a controlled furnace, maintaining temperature to ensure proper viscosity and prevent oxidation.
Injection of Molten Metal
Inject molten metal into preheated molds at high pressure for complete fill and minimal air entrapment.
Cooling and Solidification
Cool and solidify the metal in-mold, accurately forming parts with reduced distortion and shrinkage.
Mold Opening and Part Removal
Open the mold and eject the solidified part using pins, preparing it for trimming and finishing.
Main Die Casting Process Types
Our die casting encompasses several process types, each tailored to specific materials, part designs, and production needs. Below are the most common types:
Hot Chamber Die Casting
- Injection system is submerged in molten metal for faster, continuous cycles.
- Suitable for low melting point metals like tin, zinc, and lead.
- Enables short cycle times and low cost for small to medium parts.
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Cold Chamber Die Casting
- Ladled molten metal is injected into a different chamber.
- Ideal for aluminum, brass, and copper with high melting points.
- Casts larger, stronger, and more complex parts with precision.
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Available Metal Materials
We offer high-performance die casting alloys, including aluminum, zinc, magnesium, copper (brass, bronze), lead, tin, and occasionally ferrous alloys for special uses.
Aluminum Alloys
- Model: A319, A356, A380, A383, ADC6, ADC12, A360
- Corrosion-resistant and Lightweight; ideal for automotive, aerospace, and industrial use.
- Great for thin, complex parts with precise dimensions and smooth surfaces.
- Recyclable, economical, and supports anodizing, painting, and powder coating.
Zinc Alloys
- Model: Zamak2, ZA12, ZA27, Zamak3, Zamak5, Zamak7, ZA8.
- Best for small, precise parts like locks, gears, and enclosures.
- Strong, corrosion-resistant, and provides excellent plating surface.
- Low melting point extends die life and reduces machining needs.
Magnesium Alloys
- Model: AZ31B, AE42, EZ33, AZ91D, AM60B, AM50A, AS41.
- Applied in automotive, aerospace, and electronics for light structures.
- Simple machining and quick solidification for intricate pieces.
- Offers EMI shielding and heat control for electronics.
Copper Alloys
- Model: C83600, C84400, C87300, C87500, C87850, C86200, C83800.
- Ideal for plumbing, marine, and electrical precision parts.
- Offers high strength, pressure resistance, extreme environment durability.
- Easily casts details, supports multiple finishing treatments.
Surface Treatment
To improve the appearance, performance, and durability of die cast parts, we offer various surface treatments based on material, use, and finish needs.
Hot-dip Galvanizing
Immerses cast parts in molten zinc to form a tough, corrosion-resistant coating ideal for harsh outdoor environments.
Zinc Plating
Electroplates a thin zinc layer for corrosion resistance, offering a bright, smooth finish suitable for indoor applications.
Chrome Plating
Applies a chromium coating to improve surface hardness, corrosion resistance, and achieve a bright, mirror-like decorative finish.
Spray Painting
Applies liquid paint through spraying for color customization, basic corrosion protection, and improved product appearance and branding.
Powder Painting
Electrostatically coats dry powder, then heat-cured for a durable, uniform, colorful finish resistant to chips and scratches.
Polishing
Smooths and brightens the surface through mechanical or chemical methods to enhance appearance and prepare for coatings.
Anodizing
Forms an oxide layer on aluminum through electrochemical treatment, improving wear resistance, corrosion protection, and decorative appearance.
Black Oxide
Creates a black surface finish through chemical conversion, enhancing corrosion resistance, minimizing reflection, and offering slight wear resistance.
Dimensions in Die Casting
Accurate dimensional control is essential in die casting to ensure part quality, function, and compatibility with assemblies. Below are key dimensional considerations:
| Parameter | Specification |
| Maximum Part Size | Up to 1,500 mm |
| Wall Thickness | 0.5 – 10 mm |
| Draft Angle | 0.5° – 3° per side |
| Tolerances | ±0.025 – ±0.2 mm |
| Fillet Radius | 0.5 – 5 mm |
| Parting Line Offset | Up to 0.3 mm |
| Hole Diameter | 1 – 50 mm |
| Aspect Ratio | Up to 10:1 |
| Surface Roughness | Ra 0.8 – 3.2 µm |
| Shrinkage Allowance | 0.5% – 1.2% |
Tolerance for Die Casting Services
We follow industry-standard tolerances to ensure precision, though actual values vary by geometry, alloy, tooling, and casting size. Typical ranges include:
| Tolerance Parameter | Typical Range | Notes |
| Dimensional Accuracy | ±0.05 mm to ±0.3 mm | Depends on part size, geometry, and die precision |
| Wall Thickness | ±0.1 mm to ±0.25 mm | Thin sections may increase variation due to metal flow |
| Straightness | ±0.1 mm per 100 mm | Affected by cooling rate and part length |
| Flatness | ±0.05 mm to ±0.2 mm | Larger flat areas may require post-processing |
| Surface Finish | Ra 0.4 to Ra 2.0 µm | Depends on mold surface and alloy type |
| Roundness | ±0.05 mm to ±0.25 mm | Applies to cylinders, holes, and bosses |
| Angular Tolerance | ±0.1° to ±1° | Related to die alignment and feature size |
| Hole Diameter | ±0.05 mm to ±0.2 mm | Influenced by core pin stability and cooling |
| Core Pull Tolerance | ±0.1 mm to ±0.2 mm | Affected by core pull mechanism precision |
| Draft Angle | ±0.25° to ±1° | Required to release parts from mold |
| Thread Depth | ±0.1 mm to ±0.3 mm | Tolerance tighter with post-machined threads |
| Bore Tolerance | ±0.1 mm to ±0.25 mm | Applies to internal cylindrical surfaces |
| Concentricity | ±0.05 mm to ±0.2 mm | Measured between bores and outer profiles |
| Tapered Features | ±0.5° to ±1° | Supports easy mold ejection |
| Radii & Fillet Sizes | ±0.05 mm to ±0.2 mm | Tool radius and cooling rate dependent |
| Perpendicularity | ±0.2 mm per 100 mm | Maintained through precise mold alignment |
| Material Homogeneity | ±0.5% | Refers to consistency in alloy composition |
| Shrinkage Rate | ±0.2% to ±0.5% | Influenced by alloy and cooling dynamics |
| Deflection | ±0.1 mm to ±0.3 mm | May occur in long, thin-walled castings |
| Casting Distortion | ±0.1 mm to ±0.5 mm | Varies with mold temperature and part complexity |
| Coating Thickness | ±0.01 mm to ±0.05 mm | For painted, plated, or anodized surfaces |
| Gap Tolerance | ±0.05 mm to ±0.3 mm | For moving parts or sliding assemblies |
| Bead and Seam Quality | ±0.1 mm to ±0.2 mm | Impacts assembly fit and surface appearance |
Our Die Casting Parts
Applications
Our die casting solutions are widely utilized across diverse industries due to their precision, strength, and cost-effectiveness. Key application areas include:
Aerospace
Utilized for lightweight, high-strength components in aircraft structures, engine housings, and critical aerospace assemblies.
Automotive
Used extensively in automobile manufacturing for components such as engine blocks, gear housings, brackets, and structural parts.
Engine & Powertrain Components
Ideal for the production of internal combustion engine parts, oil pumps, and transmission system components requiring tight tolerances and high durability.
Motorcycle and Motor Manufacturing
Applied in the manufacturing of motorcycle frames, crankcases, and various motor housings, combining strength with lightweight performance.
Industrial Equipment & Precision Instruments
Supports high-precision components for tools, meters, and machinery, offering dimensional stability and intricate detailing.
Infrastructure & Construction
Used in power construction and landscaping tools where rugged and corrosion-resistant parts are essential.
Architectural & Decorative Applications
Enables the creation of ornamental castings and architectural details with intricate designs and consistent quality.
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FAQs
Can you die-cast large parts?
Yes, large parts can be produced using high-tonnage machines and larger molds, although tooling and setup costs are typically higher.
Is die casting appropriate for production in large quantities?
Yes, die casting’s low cycle time, reproducibility, and cost-effectiveness per unit at scale make it perfect for high-volume production.
What defects are commonly encountered in die casting?
Typical defects in die casting include porosity, cold shuts, flow marks, misruns, and surface blemishes.
Can die casting be automated?
Yes, die casting can be highly automated, including robotic part handling, alloy feeding, spraying, and trimming, increasing productivity and consistency.
What certifications are important for die casting services?
Common certifications include ISO 9001, IATF 16949, ISO 14001, and industry-specific standards depending on the application (e.g., automotive or aerospace).
What’s the lead time for die casting?
The lead time, influenced by part complexity and order volume, typically ranges from 4 to 12 weeks, from factory mold design to finished parts.