Die Casting Sourcing Services
Find a die casting manufacturing partner who can create the precision die-cast components you need. Compass & Anvil can connect you with an experienced die-cast manufacturer to handle your die-cast project from start to finish.
What is High-Pressure Die Casting?
Die Casting, also known as high-pressure die casting, is a metal product formation process that involves the pressurized filling of a mold cavity with molten metal to create a formed product. Die casting is often preferred for high-volume production runs due to its ability to deliver precision components with excellent uniformity and surface finishes.
Die Casting Process
Die casting traditionally includes four manufacturing steps:
- Die Preparation – Creation of a hardened tool mold cavity that may be lubricated for convenient removal of the final product.
- Die Filling – Molten metal is injected into a closed mold at high pressures. The pressure in the mold is maintained until the casting has reached the required level of solidification.
- Ejection –Shots are forced out by ejector pins.
- Shakeout –Shots are separated into the different components and scrap is removed. Components are generally inspected at shakeout for defects.
High pressure die casting produces products with highly accurate dimensions and relatively smooth finished surfaces that limit the amount of secondary processing that might be needed.
- Finishing operations may be required to produce specialized features such as holes, painting, polishing, plating, or buffing.
Common Die Cast Alloys and Die Cast Parts
Commonly used die-cast alloys include:
- Offers high strength and thermal conductivity. Cold formable with superior surface finishing.
- Common applications for zinc die-cast components include complex electrical housings used for automotive or electrical purposes.
- Lightweight with exceptional corrosion resistance. Has high electrical and thermal conductivity. Recyclable.
- Common aluminum die-cast parts include automotive castings, telecom parts, electrical housings.
- Magnesium offers thin wall capabilities with high electrical and thermal conductivity. Magnesium cast parts also offer high stability and dimensional accuracy.
- Common magnesium die-cast applications include electronic parts, medical device components, and lab equipment.
Die Casting Advantages
Die casting offers several advantages including the following:
- Highly accurate, complex shapes for high-volume production runs
- Complex shapes/designs with tight tolerances are achievable without added tooling
- Heat resistance with multiple finishing surface options
- Prevent RF emissions when compared to plastic injection molding
- Requires less machining than sand castings
- Tighter dimensional tolerances when compared to forgings