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Die casting

Die casting is a metal casting process characterized by forcing molten metal under high pressure into a mold cavity. Cavities are created using two hardened steel molds or other materials that are machined to the desired shape according to the customer design and then coated with a release agent to allow for easy removal of the casting.

The process begins by melting the metal in a furnace, which is then heated to a temperature above its melting point. After melting, the metal is filled or injected into the injection chamber, and a hydraulic piston is used under high pressure to force the metal from the injection chamber into the mold cavity.

As the molten metal cools and solidifies, the mold opens and the casting is released from the mold. The casting can then be subjected to secondary operations such as trimming, machining or surface finishing to obtain the desired end product.

Die casting is an efficient and precise process for producing complex shapes with high dimensional accuracy and surface finish. It is commonly used in manufacturing automotive, aerospace and consumer electronics industries, food processing, aviation, seals/gaskets, lighting, packaging, filters, healthcare, telecommunications, machinery, water treatment, appliances, entertainment, lawn and garden, education , oil and gas, government, construction, pipeline, surveillance, pumps, ships, motors, gears, RFID tags, electronics and fasteners.

Mold Material Aluminum,45#, P20, H13, 718, 1.2344, 1.2738 and so on
Material Aluminum Alloy ADC12 ,A380

Zinc: ZA3#, ZA5#, ZA8#, etc

Magnesium: AZ91D, AM60B, etc.

Or as customer’s request

Film Standard Powder coating: 60-120 μ , Electrophoresis film: 12-25 μ.
Part Weight from 3 g — 20kgs
Surface Treatment Mill-Finished, Powder Coating, Polishing, Brushing, etc.
Drawing format IGES, STEP, AutoCAD, Solidworks, STL, PTC Creo, DWG, PDF, etc..
Deep Processing CNC / Cutting / Punching / Checking / Tapping / Drilling / Milling

Advantages of die casting:

  1. High production efficiency: Die casting is a high-speed, automated process that can produce a large number of parts quickly and consistently.
  2. Excellent dimensional accuracy: The parts produced by the die-casting process have small tolerances and high dimensional accuracy. The die-casting process is suitable for the manufacture of metal parts with complex shapes, clear outlines, thin walls and deep cavities. Since the molten metal maintains high fluidity under high pressure and high speed, metal parts that are difficult to process by other processes can be obtained. The dimensional accuracy of die castings is strictly required, which is generally equivalent to grade 6~7, and even up to grade 4.
  3. Superior surface finish: Die cast parts have a smooth surface finish that requires little to no secondary finishing.It has good surface finish, generally equivalent to 5~8 level.
  4. High strength and durability: Die cast parts have excellent strength and durability, making them ideal for use in applications that require high performance and reliability.Compared with sand casting, the strength of die casting is generally increased by 25~30% , but the elongation is reduced by about 70%.
  5. Cost-effective: The die casting process is cost-effective for producing high-volume parts due to its high production efficiency and low material waste.

Disadvantages of die casting:

  1. Limited material selection: The die casting process is limited to the use of metals with low melting points, such as aluminum, zinc, and magnesium.
  2. High tooling and equipment costs: The cost of tooling and equipment required for die casting can be high, which can make it less suitable for producing small quantities of parts.
  3. Die casting is not suitable for small batch production. The main reason is that the manufacturing cost of die casting mold is high. The production efficiency of die casting machine is high and it is not economic for small batch production.


die casting process

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