What is Pressure Die Casting

Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds, it offers an economical way of producing large quantities of complex, high tolerance parts in aluminium, magnesium, zinc and copper alloys. The material has to withstand both pressure and high temperatures. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

Advantages of 

Pressure die casting

  • Very good surface finish

  • Economical for large scale production.

  • Possible to obtain fairly complex castings

  • Small thicknesses can be easily filled asthe liquid metal

  • Closer dimensional tolerances & better mechanical properties

  • High speed production can be achieved asthe whole process is completely automated

Our Pressure Die Casting service

Our team of Machine Operators, Process Control Technicians, and Quality Personnel all work together to ensure our casting machine output meets or exceeds industry standards and customer specifications. We also perform a variety of secondary operations such as sanding, milling, drilling, tapping and assembly.

Hard tool or H-13 die cast tooling is an excellent process for higher quantity requirements. A larger upfront tooling investment yields a significant reduction in re-occurring costs. Production die cast parts have highly repeatable properties and tolerances.

Typical Lead Time

  • Tooling = 4 weeks
  • Samples = 1-2 weeks
  • Production (Qty 10k) = 3-4 weeks

Tooling Life Expectancy

  • 300k shots

The term “Soft Tool” is used to describe a die cast tool made out of P-20 steel. The P-20 steel is softer than H-13 steel and thus yields parts in less time with a decrease in tooling cost attributed to the ability to run faster feed rates when CNC machining the tool. Typically a P-20 tool can yield 10,000-40,000 parts before showing any significant wear.

Typical Lead Time

  • Tooling = 2 weeks
  • Samples = 1-2 weeks
  • Production (Qty 100) = 3-5 days

Tooling Life Expectancy

  • 10k shots

We routinely pour a broad range non-ferrous materials. The following are some of the most common alloys being used:

  • Aluminum die casting alloys: A380, A360, A356, and K-Alloy
  • Magnesium die casting alloys include AZ91D and AM60B
  • Zinc die casting alloys include ZA3, ZA12, and ZA27
  • Copper alloy die castings

  • As cast tolerance as tight as +/- .005”, post machining available for tighter tolerance applications.
  • Standard tolerance of +/- .010” for the first inch and +/-.002” each additional inch.
  • Typical surface finish of Ra 63-125 micro-inch as cast, post machining available for higher quality finishes.
  • Minimum draft = .5 degrees
  • Minimum wall thickness = .030” (Thinner wall thickness possible with alternative processes)