Aluminum Die Casting — High Volume, Net Shape
From drawing review to volume production, we manufacture tight-tolerance die cast components for demanding OEM applications. Housings, brackets, heat sinks, and structural parts — direct from our China factory.
For Procurement
MOQ, lead time, packaging and commercial terms — go straight to a quotation.
Submit a Drawing →For Engineering
Grades, drawings, process data and design support for your DFM review.
Manufacturing Capability →For Quality / SQE
Certificates, inspection planning, traceability and PPAP / FAI support per project.
Certificates & Documentation →From Drawing to Production
Every die casting program runs the same engineering-first route.
Drawing
You send STEP / PDF drawings, alloy preference and annual volume.
DFM Review
Engineers check draft, wall thickness, undercuts and machining stock.
Tooling
Die design and manufacture — tool remains your property.
Prototype
First shots for your validation before production release.
FAI
First Article Inspection on dimensions, porosity and appearance.
Mass Production
Stable cycle with vacuum assist and process controls as required.
Inspection
Dimensional sampling by gauge / CMM per the agreed inspection plan.
Shipment
Packaging to your spec, with inspection and compliance documents.
Why Die Casting?
When your volume justifies tooling, die casting delivers the lowest cost per complex aluminum part.
- ✓Complex geometry, net shape — thin walls, internal features, and near-net external geometry in a single operation
- ✓High production rate — a die cast cycle takes 30–90 seconds — thousands of parts per day from one tool
- ✓Excellent dimensional repeatability — ±0.1mm on as-cast features; consistent part-to-part
- ✓Integrated functions — cast-in inserts, bosses for fasteners, EMI shielding, and heat sink fins in the part design
Applications
| Application | Typical Spec | Why This Material |
|---|---|---|
| Electronics Housings | A380, powder coated | EMI shielding + thermal management + structure |
| Motor Housings | ADC12, machined bore | Precision motor end bells and shells |
| Automotive Brackets | A360, heat treated | Structural components with tight tolerances |
| LED Lighting | ADC12, anodized | Thermal management housings for high-power LEDs |
| Power Tools | A380, painted | Lightweight structural housings |
Die Casting Capabilities
Alloy datasheets available for download.
| Parameter | Capability | Notes |
|---|---|---|
| Alloys | A380, ADC12, A360, A413, Zamak 3/5 | AlSi-based aluminum + zinc alloys |
| Part size | 0.05–20 kg | Hot and cold chamber machines |
| Clamping force | 50–4,400 tons | 8 machine sizes |
| Wall thickness | 1.0–2.5mm typical (0.8mm minimum) | Thinner possible with vacuum assist |
| Tolerance | ±0.1mm per 25mm (as-cast) | CNC machined features to ±0.01mm |
| Surface finish | Ra 1.6–3.2µm as-cast | Polished or textured mold surfaces |
| Secondary ops | CNC machining, tapping, anodizing, powder coat, e-coat | In-house and managed partners |
Materials We Cast
Our standard aluminum and zinc casting alloys — selected with you during DFM review:
| Alloy | Family | Character |
|---|---|---|
| A380 | Al-Si-Cu | Workhorse — best all-round castability and strength |
| ADC12 | Al-Si-Cu | Asian equivalent of A380, excellent fluidity |
| A360 | Al-Si | Higher corrosion resistance, good pressure tightness |
| A413 | Al-Si | Optimized for pressure-tight and thin-wall parts |
| Zamak 3 / 5 | Zn | Very small parts with tight as-cast tolerances |
Other alloys considered per project — confirm availability with engineering.
Tolerance & Surface Finish
Realistic as-cast values — we confirm achievable tolerances per feature during quotation:
| Feature | Typical Capability |
|---|---|
| As-cast linear tolerance | ±0.1 mm per 25 mm |
| CNC-machined features | ±0.01 mm |
| As-cast surface finish | Ra 1.6–3.2 µm |
| Minimum wall thickness | 0.8 mm (1.0–2.5 mm typical) |
| Draft angle | 0.5°–2° per side by depth |
Tighter requirements are reviewed case by case — ask engineering before specifying.
Inspection & Quality Documentation
Inspection scope is agreed per project in the inspection plan.
Dimensional
Calibrated gauges and CMM measurement on critical dimensions per the agreed sampling plan.
Material & Surface
Alloy certificates from the casting lot; surface roughness and coating verification where specified.
Project Documentation
FAI reports and PPAP documentation per project requirements; RoHS / REACH declarations on request.
DFM for Die Casting
Design decisions that save cost and improve quality:
- ✓Uniform wall thickness — avoid thick sections that cause porosity and sink marks; use ribs for stiffness instead of mass
- ✓Draft angles — 0.5°–2° per side depending on depth — required for part release from the die
- ✓Undercuts — minimize — each undercut adds a slide mechanism that increases tooling cost and maintenance
- ✓Machining stock — specify 0.3–0.5mm stock on machined faces; die cast surfaces may be porous under the skin
Porosity & Solutions
Die casting inherently traps some gas — manage it with design and process:
- ✓Vacuum assist — evacuating the die cavity before injection reduces gas porosity by 60–80% — required for pressure-tight or machined-surface parts
- ✓Impregnation — resin impregnation seals micro-porosity for pressure-tight applications (Type I anerobic or Type II thermoset)
- ✓Design for porosity — locate machined surfaces away from last-to-fill regions; specify porosity acceptance criteria in your drawing
Application Gallery
Real applications of Aluminum Die Casting across industries.
Case Study — A380 Die Cast Housing
See how we consolidated die casting, CNC finishing and anodizing under one quality system for an electronics housing program.
Frequently Asked Questions
What alloys should I choose?
A380 (US standard) and ADC12 (Asian equivalent) are the workhorses — excellent castability, good mechanical properties. A360 offers better corrosion resistance for marine applications. A413 optimizes for pressure tightness. Zamak (zinc) for very small, tight-tolerance parts. We'll recommend based on your requirements.
How much does tooling cost?
Die casting tools run $5,000–$50,000+ depending on part size, complexity (slides for undercuts), and expected tool life. High-volume tools use H13 steel and last 100,000–500,000 shots with maintenance. We provide tooling quotes with each part quote — and the tool is your property.
What's the MOQ for die casting?
Practical minimum is 500 pieces per order — below that, tooling amortization dominates part cost. For prototypes (10–100 pieces), we recommend CNC machining from billet, then transitioning to die casting at production volume. Our DFM review includes this trade-off analysis.
Can die cast parts be anodized?
Yes, with caveats: high-silicon alloys (A380, ADC12) anodize to a gray/bronze finish with some cosmetic variation. For decorative clear or colored anodizing, we recommend A360 or low-silicon alloys. For pure corrosion protection, powder coating or e-coat works well on all alloys.
Have a Drawing?
Send it to our team for engineering review and quotation — DFM feedback and alloy recommendation included.