Precision Custom Die Casting Services
We specialize in high-pressure die casting for complex, high-volume production. From rapid prototyping to final part delivery, our process ensures excellent surface finish, tight tolerances (as low as ±0.001"), and cost-effective manufacturing solutions. Get functional prototypes in as fast as 5 days or production runs with secondary operations - all from a single reliable partner
Precision Die Casting Capabilities
Comprehensive technical specifications for our aluminum and zinc die casting services.
| Technical Parameter | Aluminum Die Casting | Zinc Die Casting |
|---|---|---|
| Common Materials | A360, A380, ADC12, ALSI12 | Zamak 3, Zamak 5, ZA-8 |
| Max. Projected Area | 600 cm² | 400 cm² |
| Clamping Force | 80 - 630 Tons | 80 - 400 Tons |
| Max. Part Weight | 2.5 kg | 1.5 kg |
| Typical Wall Thickness | 1.5mm - 5.0mm | 0.5mm - 3.0mm |
| Standard Tolerance (±) | ±0.15 mm (first 25mm) | ±0.10 mm (first 25mm) |
| Best Achievable Tolerance (±) | ±0.05 mm | ±0.025 mm |
| Typical Surface Roughness | Ra 1.6 - 3.2 μm | Ra 0.8 - 1.6 μm |
| Average Mold Life | 150,000 - 300,000 shots | 500,000 - 1,000,000 shots |
Gallery Of Pressure Die Cast Parts
Types of Die Casting Processes
We specialize in both high pressure die casting for complex, high-volume aluminum parts and low pressure die casting for larger, more structurally sound components - delivering precision, quality and cost efficiency。
High Pressure Die Casting (HPDC)
This method involves injecting molten metal into the mold cavity at very high pressure, typically above 1000 bar. It is ideal for creating thin-walled and complex-shaped parts with high dimensional accuracy.
Low Pressure Die Casting (LPDC)
LPDC uses lower pressure (typically 2-5 bar) to slowly fill the mold from the bottom. This method is suitable for larger parts that require a smooth, uniform structure, such as wheels and large housing components.
Available Materials For Die Casting
Choosing the right material is crucial for successful die casting projects. We work with 3 primary materials - aluminum, zinc, and magnesium alloys - each offering distinct advantages for different applications. Our expertise helps you select the optimal material based on your specific requirements for strength, weight, corrosion resistance, and cost-effectiveness.
| Material Type | Common Grades | Key Properties | Typical Applications |
|---|---|---|---|
Aluminum Alloys
|
A380, ADC12, A360, A383 | Lightweight, good corrosion resistance, excellent strength-to-weight ratio, high thermal and electrical conductivity | Engine components, transmission housings, electronic enclosures, heat sinks |
Zinc Alloys
|
Zamak 3, Zamak 5, ZA-8 | Excellent casting fluidity and dimensional stability, high impact strength, good plating capability | Electronic connectors, gears, automotive components, hardware fittings |
|
Magnesium Alloys
|
AZ91D, AM60B | Extremely lightweight, excellent strength-to-weight ratio, good damping capacity | Laptop cases, camera bodies, automotive instrument panels, aerospace components |
Available Surface Finishes For Die Casting
Choosing the right surface finish enhances both the appearance and performance of your die cast parts. We offer various finishing options including anodizing, powder coating, and electroless nickel plating to meet different application requirements. Each process provides unique benefits for corrosion protection, wear resistance, and aesthetic appeal.
| Surface Finish | Process Description | Key Benefits | Common Applications |
|---|---|---|---|
Polishing
|
Mechanical abrasion to create a smooth, reflective surface | High-gloss finish, improved aesthetics, smooth tactile feel | Decorative trim, consumer products, architectural elements |
Anodizing
|
Electrochemical process that creates a durable, porous oxide layer | Excellent corrosion resistance, wear resistance, available in various colors | Automotive parts, aerospace components, electronic housings |
Electroless Nickel Plating
|
Autocatalytic chemical process that deposits a uniform nickel-phosphorus alloy coating | Excellent uniformity on complex geometries, high hardness, superior corrosion and wear resistance | Hydraulic components, molds, valves, shafts, electronic enclosures |
Powder Coating
|
Electrostatically applied dry powder cured under heat to form a protective layer | Extremely durable, wide color selection, resistant to chipping and fading | Outdoor equipment, machinery enclosures, automotive wheels |
Chromate Conversion
|
Chemical process creating a protective film, typically iridescent yellow or olive drab | Cost-effective corrosion protection, good paint base, electrical conductivity | Electronic components, fasteners, military hardware |
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Specialist Industries
We have manufactured millions of parts for various applications, with particular expertise in the following areas.
FAQ
MOST FREQUENT QUESTIONS AND ANSWERSQ1: What materials can be used in pressure die casting?
A1: Common materials include aluminum, zinc, magnesium, and copper alloys, chosen for their properties like strength, lightweight, and corrosion resistance.
Q2: What is the difference between high pressure and low pressure die casting?
A2: High pressure die casting uses high force to inject molten metal into the mold, suitable for thin-walled parts, while low pressure die casting uses lower pressure, ideal for producing larger parts with uniform structures.
Q3: What are the typical tolerances for pressure die casting?
A3: Tolerances can range from ±0.05 mm to ±0.15 mm for linear dimensions, depending on the part’s geometry and material.
Q4: What surface finishes are available for die-cast parts?
A4: Common finishes include powder coating, anodizing, electroplating, painting, and polishing, enhancing appearance, corrosion resistance, and mechanical properties
Q5: How complex can die-cast parts be?
A5: Pressure die casting is ideal for producing intricate shapes with complex geometries, thin walls, and tight tolerances that would be difficult to achieve with other processes.
Q6: How long does a pressure die casting mold last?
A6: Mold lifespan depends on the alloy and production volume. On average, a mold can produce between 50,000 to 100,000 cycles for zinc and 100,000 to 200,000 cycles for aluminum.
Q7: What are the advantages of using pressure die casting?
A7: It offers high production efficiency, excellent dimensional accuracy, smooth surface finishes, and the ability to create complex shapes in a single process.
Q8:Can pressure die casting achieve tight tolerances?
A8: Yes, it can produce parts with high dimensional accuracy, typically achieving tolerances within ±0.1 mm for most applications.
Q9: What are the common defects in pressure die casting?
A9: Typical defects include porosity, shrinkage, and misalignment, but can be minimized through process optimization, quality control, and proper mold design.