Precision Aluminium Die Casting for Complex and Durable Components

Common die-casting alloys are ADC12 (JIS), A380 and A383 (ASTM), LM24 (BS 1490), EN AC-46000 and LM6 / A413 for thin, pressure-tight parts. A360 is used where better corrosion resistance and strength at temperature are needed.

High-pressure die casting fills the die in milliseconds at high pressure, allowing very thin walls and high volumes but with some entrapped porosity. Gravity die casting fills more slowly, giving denser parts that can be heat treated (T6), but with thicker walls and slower cycles.

Walls of 1.5–3 mm are typical in high-pressure die casting, and features down to about 1 mm are possible on small parts. Uniform wall thickness with generous fillets reduces porosity, shrinkage and distortion.

As-cast tolerances typically fall within ISO 8062 CT5–CT7, roughly ±0.1–0.2 mm on dimensions up to 100 mm. Features that need tighter tolerances, such as bores and sealing faces, are CNC machined after casting.

Conventional HPDC parts contain entrapped gas that can blister during solution heat treatment or welding, so they are normally used as-cast or with low-temperature stabilizing. Where heat treatment or welding is needed, gravity or vacuum-assisted die casting is recommended.

Porosity is minimized through die design (gating, overflows and venting), controlled metal temperature, degassing, vacuum assistance where required and process simulation. Critical parts can be X-ray inspected, leak tested and vacuum impregnated.

Powder coating, wet painting, chromate or trivalent conversion coating, e-coating, shot blasting and polishing are common. High-silicon die-casting alloys do not anodize to a decorative finish, so powder coating is preferred for cosmetic parts.

Draft of 1–2° on external walls and 2–3° on internal cores is typically required for ejection. Deeper features need more draft. Our engineers review your 3D model and suggest draft and fillet changes before die design.

Tool cost depends on part size, cavities, slides and complexity. A well-maintained H13 steel die typically produces 80,000–150,000 aluminium shots or more before major refurbishment. Tooling paid for by the customer remains the customer's property.

Die casting becomes economical from a few thousand parts per year upward because tooling cost is spread over the volume and cycle times are short. For lower volumes, gravity or sand casting, or CNC machining from billet, may be more cost-effective.

Yes. We trim, deburr, CNC machine, tap, leak test, coat and assemble die castings in-house, supplying ready-to-fit components rather than raw castings.

We carry out first-article inspection, spectrometer checks of each melt, dimensional inspection with gauges and fixtures, visual and X-ray inspection where specified, and leak testing for pressure-tight parts. Reports are supplied on request.

Motor and gearbox housings, pump bodies, LED and lighting housings, electrical enclosures, heat sinks, automotive brackets and covers, power-tool bodies, electrical connectors and appliance components.

Please share the 3D model (STEP), 2D drawing with critical dimensions, alloy, surface finish, machining requirements, leak-test or X-ray criteria and annual quantity. We will reply with tooling cost, sample lead time and piece price.