Manufacturing Processes

Die Casting

Die casting (also known as High Pressure Die Casting) is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool-steel dies which have been machined into shape and work similarly to an injection mold. Our die castings are made from non-ferrous metals, specifically zinc, aluminum, and magnesium based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the process to higher volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small to medium sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.

If you're looking for the most economical, efficient technology to produce your design in a durable and rigid metal form, the high pressure die casting process may be the solution. Parts can range in size from as small as 1" x 1" up to 24" x 24". It provides a broader range of shapes and components than many other manufacturing technique. In addition, the high pressure die casting process provides a high degree of dimensional accuracy and offers:

Production of complex shapes with tight tolerances
Thin wall castings
High production rates
Long service life
Lowest per part piece price of all casting processes

Aluminum Die Castings - A 380 (with various Heat Treatments)

Lightweight
Retain high dimensional stability with thin walls and complex shapes
Corrosion resistant
Good mechanical properties
High thermal and electrical conductivity
High strength - even at high temperatures

Magnesium Die Castings AZ91D

Longer tool life
Easiest alloy to machine
Good thermal conductivity
Excellent for thin-wall, complex parts

Zinc Die Castings (including Miniature Zinc Die Castings) - Zamac #3 and ZA-8

Complex shapes with thinner walls
Superior mechanical and physical properties with excellent tensile strength and dimensional stability
Excellent RFI/EMI shielding capabilities
Longer die life with minimal maintenance
Exceptional as-cast cosmetic finish resulting in a multitude of finishing/plating/painting options