Die casting is a manufacturing process that produces high volumes of complex and tight-tolerance metal parts with a high strength-to-weight ratio. Thin wall die casting excels in creating stronger and lighter parts when compared with other casting methods.

As for non-ferrous alloy thin wall castings, the wall thickness can range from 2.0 to 4.0 mm. There is ultra-thin wall die casting with a wall thickness of less than 2.0 mm, which is often seen on aluminum alloy castings. Thin wall die casting is characterized by high production efficiency and excellent dimensional accuracy. It can create thin wall deep cavity castings for complex shapes with clear tours economically.

In Echofast, we mainly offer custom thin wall die-casting services with aluminum alloys. We can produce strong yet light parts for your thin wall casting needs.

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Applications of Thin Wall Die Casting

Thin wall die casting is used in a wide range of industries due to its ability to produce lightweight and durable parts.

  • Automotive
  • Aerospace
  • Manufacturing
  • Medical
  • Military
  • Commercial

Echofast Thin Wall Die Casting Materials

AluminumADC12Excellent corrosion resistance and mechanical properties; widely used in various applications such as automotive components and consumer goods.
A380Commonly used in automotive parts, electronic housings, and consumer goods.
A360Offers good castability and machinability, suitable for intricate designs and thin-walled structures.
383Known for superior fluidity and pressure tightness, ideal for thin-wall casting applications.
A413Utilized in automotive parts, electrical connectors, and industrial equipment.
B390Exhibits excellent thermal conductivity and mechanical properties, suitable for heat transfer applications.
518High thermal conductivity and dimensional stability, suitable for heat sinks and electronics.
ZincZamak 3Known for excellent castability, dimensional accuracy, and surface finish.
Zamak 5Exhibits improved strength and hardness, suitable for a variety of applications.
MagnesiumAZ91DGood strength-to-weight ratio, excellent corrosion resistance, and machinability.
AZ91HPFeatures enhanced creep resistance and thermal stability, ideal for high-pressure die casting.
AM60BProvides excellent ductility and impact resistance, suitable for automotive and sporting goods.

Advantages of Thin Wall Die Casting

  • Excellent strength-to-weight ratio
  • Achievable net shape configuration
  • Tight tolerances and high dimensional accuracy
  • Efficient production
  • Smooth surfaces (less machining)
  • Nice surface finish
  • Complex shapes
  • Large sizes
  • Reduced assembly

Disadvantages of Thin Wall Die Casting

  • High initial cost due to prototyping and tooling requirements
  • More porosity
  • Tighter tolerances: Required for fillets/radii and drafts

Need affordable mold services?

Price is a challenge in die casting, especially for molds. Echofast offers highly competitive prices (10% below market price), making our services affordable for small manufacturers. You can talk to our mold experts, discuss your product idea, discover its manufacturability, and get the sample.

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Available Die Casting Finishes

Alternatives to Thin Wall Die Casting

Mold Making Services FAQs

After receiving the order, the statement of work is reviewed by our case manager.A comprehensive DFM/PEG/mold flow analysis report is created and provided for approval.Upon approval, mold production is commenced.T1 samples are produced and shipped within the specified time for approval.Upon approval, molds can be shipped.

In most cases, it’s about 30 days for molds with simple structures, but the specific time is mainly based on the mold structure.

Die casting can achieve tight dimensional tolerances, typically ranging from ±0.005 to ±0.020 inches, depending on the part design and casting process capabilities. Tighter tolerances may be achievable with additional machining or secondary operations.

The maximum size and weight of die castings depend on the capabilities of the die casting equipment and the specific alloy being used. Generally, die castings can range from small, intricate components to larger parts weighing several kilograms.

Die castings exhibit excellent mechanical properties, including high strength, stiffness, and impact resistance. The specific mechanical properties depend on the alloy composition, heat treatment, and casting process parameters.

Yes, die castings can be customized to meet a wide range of design requirements, including complex geometries, special surface finishes, and functional features. Custom tooling and mold designs are often used to achieve unique part configurations.

Die casting is generally cost-effective for large production volumes due to its high-speed production capabilities, minimal material waste, and low labor costs per part. Compared to other manufacturing methods such as machining or forging, die casting often offers competitive pricing.

The quality control process for Die castings involves rigorous inspections and testing at various stages of production, including material testing, dimensional inspections, and visual inspections. Advanced techniques such as X-ray inspection, pressure testing, and metallurgical analysis may also be employed to ensure the quality, reliability, and consistency of die castings.

Die casting offers several advantages, including high strength-to-weight ratio, excellent dimensional accuracy, and the ability to produce complex shapes with tight tolerances. It is also cost-effective for large production volumes and provides good surface finishes.

Die casting is one of the most cost-effective metal casting process. Though it takes more time to manufacture die-cast molds, a single mold can yield thousands of product units. At Echofast, we specialize in Die casting and offer discounted rates for large quantity orders.

The most significant difference between die casting and sand casting is the material used for molding. die castings employ molds crafted from alloy, whereas sand casting relies on molds made of sand.

Sand casting excels in managing intricate designs, while die casting prioritizes superior dimensional precision and efficiency. Additionally, sand casting yields thicker walls compared to die casting, which is adept at producing thinner walls. Consequently, sand casting may not be viable for smaller components.

It depends on the structure and the size of the products,and we will judge the number of cavities at the maximum limit of the multi-cavity range.

+/- 0.005″ when machining the mold and an additional +/- 0.002″ per inch when calculating for shrink rate.

Die casting mold is used across a wide range of industries including automotive, industrial, security , 5G communication equipment, motor housing , pump body & valve, and more.