What is Die Casting?

Die casting is a manufacturing process that forces molten metal into a mold cavity under high pressure to create large quantity of high-performing complex metal parts. The process requires a reusable steel mold for production, which is called a die casting mold. The mold consists of two sections clamped together, one stationary and one moveable.

As the molten metal in the mold cavity takes the shape of the part and hardens into place, the halves are separated to remove the casting. Common alloys used in die casting include zinc, copper, aluminium, magnesium, lead, pewter, and other non-ferrous alloys.

Die casting is a relatively simple process and well suited for the high-volume production of small-to medium-sized castings. Die casting parts can be made with tight tolerances and good surface finish, requiring few secondary operations.

 Advantages of Die Casting

  • Excellent dimensional accuracy
  • Smooth cast surfaces
  • Reduce  or  eliminate  secondary  machining  operations
  •  Complex  thin-walled  parts
  • Good mechanical properties
  • Cost-Effective for high volume production

Disadvantages of Die Casting

  • Easily generate porosity
  •  Usually support non-ferrous metals only
  • Not suitable for low volume production
  • Low die life
  • Large capital investment
  • Time -consuming
  • Produce hazardous waste
  • Labor intensive

Die Casting Mold Design Process

Designing a mold involves processes that come with multiple categories.

  • Preparation Phase: This is the phase where the validity of the product is evaluated from a dimensional and geometrical standpoint.
  • Cavity Numbers: Cavity orientation, product count, and hypothetical time cycle have to be considered for the cavity mold’s best option.
  • Projection Place: Projection has a significant role in the designing phase. It is also where the surface is created from the cavities plan.
  • Die Volume & Shape: Volume and shape are essential in mold design. Here, the cavities’ sizes can be molded accurately.
  • Simulation: This helps calculate the mold filling method. The modality depends on the filling process and process of the cast piece.

Die Casting Types Available from Echofast

Cold chamber die casting, also referred to as cold casting, involves melting metal in a separate furnace and subsequently pouring the molten metal into an unheated chamber for injection into the mold under high pressure. It is the preferred die casting process for metals with higher melting temperatures, such as aluminum, magnesium, and copper alloys.

Hot chamber die casting, also known as gooseneck casting, is a fast-cycling casting process for metals with low melting points (i.e. Zinc, some Magnesium alloys). The molten metal is injected into the die mold under high pressure, where it rapidly solidifies into the desired shape before being ejected as a fully formed component.

What Material Grades Are Available For Die-Casting?

Aluminum die casting is a manufacturing process where the molten aluminum alloy is forced into a mold under high pressure to create parts. To meet the unique needs of different die casting projects, Echofast selects aluminum alloys carefully on the basis of the specific requirements of the application, including mechanical properties, surface finish, dimensional accuracy, and cost considerations.

Commonly used aluminum alloys in Echofast:

  • ADC12
  • A380
  • A360
  • 383
  • A413
  • B390
  • 518
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Zinc die casting is the process of forcing molten zinc alloys into a mold with high pressure to form a required shape. With its excellent properties, zinc die casting has become one of the most efficient and versatile high-production methods in production. The process is often used to produce high-quality, intricate metal parts across diverse industries due to their excellent mechanical properties.

Commonly used zinc alloys in Echofast:

  • Zamak 3 
  • Zamak 5
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Magnesium die casting is a manufacturing process that involves the injection of molten magnesium into a mold cavity under high pressure. At Echofast, we meticulously select magnesium alloys based on the specific requirements of our customers. We have the expertise to adjust the alloy composition to achieve optimal toughness, ductility, and impact resistance tailored to the application of the casting.

Commonly used magnesium alloys in Echofast:

  • AZ91D
  • AZ91HP
  • AM60B
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Copper die casting is a manufacturing process that involves injecting molten copper into a mold to create complex copper parts. It is a splendid process to manufacture die casts with high hardness, high corrosion resistance, good wear resistance, good and dimensional stability. Pure copper is not commonly used in die casting as it is prone to cracking, shrinkage, and porosity. Instead, copper alloys are more often used.

Commonly used copper alloys in Echofast:

  • Brass
  • Bronze
  • Beryllium copper 
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Case Studies

Case Study: Aluminum Die Casting Heat Sink

Project details As a company lacks of the experience in manufacturing heat sinks used for communication equipment, it cooperates with Echofast to meet rapid production needs. Case Analysis Heat sink…

Case Study: Aluminum Die-casting Gearbox Housing

Project details To create large quantities of high-quality gearbox housing at a lower cost, an automotive manufacturer works with Echofast due to our splendid die casting services. Case Analysis As…

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.