High-Pressure Die Casting Solutions
Die Casting dominates automotive, electronics, and industrial equipment sectors for mass production. Key parts:
- Engine transmission housings
- Heat sink assemblies
- Power tool body frames
- LED lighting enclosures
- Pump and valve bodies
- Aerospace sensor casings
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Service
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High-Pressure Die CastingProduces thin-walled complex parts (e.g., engine housings) with rapid high-pressure injection. Achieves high precision but may cause porosity. -
Vacuum-Assisted Die CastingRemoves mold air pre-injection to minimize porosity, enhancing part integrity. Ideal for critical EV battery enclosures requiring durability, though tooling costs exceed standard methods. -
Semi-Solid Die CastingUses partially solidified slurry (30-60% solid) to minimize shrinkage. Perfect for aerospace valves but needs precise temperature control. -
Squeeze Die CastingApplies extreme pressure (1,000+ MPa) post-filling to eliminate voids. Produces dense parts like wheel hubs but requires strong molds.
Our Precision Die Casting Parts
Specializing in aluminum/zinc die casting (100-3000T machines), we produce high-volume components with ±0.1mm tolerances and 1.5μm surface finish. Our automated cells yield 50,000+ monthly parts for automotive, IoT, and consumer electronics, featuring thin walls (0.6mm), threaded inserts, and customized alloys
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10+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
210+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
310+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest
Die Casting Materials
High-pressure casting of aluminum A380, zinc ZAMAK 3, and magnesium AZ91D with ±0.25mm tolerances. Multi-slide machines produce thin-wall (1.2mm) components for automotive and IoT housings with Class A surface finishes.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Lightweight (1/3 density of steel), high strength-to-weight ratio, excellent thermal conductivity, and corrosion resistance; widely used in automotive, aerospace components, and electronic housings (e.g., engine parts, heat sinks).
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Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
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Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
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High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
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High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
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Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
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Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
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Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
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Low melting point (400–430°C), high ductility, ideal for thin-walled precision parts and surface-finish-critical products, including hardware, locks, and electroplated decorative components.
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Lightest structural metal with high strength-to-weight ratio and vibration damping; applied in aerospace, 3C electronics, and lightweight components (e.g., drone frames, laptop housings).
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High wear resistance and conductivity, but challenging to process and costly; primarily used in high-temperature/wear-resistant applications (e.g., electrical contacts, marine components).
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Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
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Die Casting Tolerances and Standards
With precision die casting services, Worldsoaring is your ideal partner to create precision machined prototypes and parts tolereance is down to±0.0004 in. We can also achieve special tolerances as long as you indicate your requirements for your drawing.
Die Casting Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
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As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
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AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
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AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
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Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
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BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
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EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
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Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
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ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
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ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
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GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
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Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
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KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
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Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
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OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
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PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
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PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
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Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
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PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
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PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
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Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
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CNC Machining Project
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Upload a CAD file to receive instantly quotes, lead time, and DFM details for your CNC components. Specializing in CNC machining for metals and plastics, we provide adaptive production and shipping solutions to align with your product development needs.
What is Die Casting?How Does Die Casting Work?
Die Casting is a high-pressure metal casting process that forces molten metal (e.g., aluminum, zinc, or magnesium alloys) into a reusable steel mold (die) to produce precise, complex-shaped parts. Known for its efficiency and repeatability, it creates components with excellent surface finish, dimensional accuracy, and structural integrity. Common applications include automotive parts, electronic housings, and industrial machinery components.
Die Preparation:A two-part steel mold (die) is preheated and coated with lubricant to facilitate part release and cooling. The die is clamped under high pressure to withstand molten metal injection.
Metal Injection:Molten metal is melted in a furnace (e.g., aluminum at 600–700°C) and injected into the die cavity at high pressure (10–210 MPa).In hot-chamber die casting (for low-melting-point metals like zinc), the injection system is submerged in molten metal. Cold-chamber die casting (for aluminum/magnesium) uses a separate chamber.
Cooling & Solidification:The metal rapidly cools and solidifies within the die, retaining the mold’s intricate details. Cooling channels in the die regulate temperature to minimize defects like porosity.
Ejection & Finishing:The die opens, and ejector pins release the solidified part.Excess material (flash, sprues) is trimmed, and surfaces are polished, painted, or plated for enhanced aesthetics and functionality.
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CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Die Casting Projects
FAQs
What is the difference between die casting and Mould casting?
Die casting injects molten metal at 10-175MPa pressure into steel molds, achieving ±0.05mm tolerances and 1.6-12.5μm surface finishes. Gravity
casting relies on atmospheric pressure, resulting in ±0.5mm tolerances and 25-50μm finishes. Die casting suits high-volume production (500-1000
shots/day) of complex geometries, while mold casting is preferred for low-volume, large components with simpler designs.
How do you make a die cast Mould?
Die cast mold manufacturing follows a rigorous 5-stage process:
CAD design validation (DFM analysis)
CNC machining of hardened steel blocks (±0.01mm accuracy)
Cooling channel integration (conformal or baffle designs)
Surface enhancement (nitriding, polishing to Ra 0.2μm)
Trial runs with thermal imaging for hotspot detection.
This ensures dimensional stability under cyclic thermal stress (ΔT 300-700°C).
What Mould are used in die casting?
Die casting utilizes high-grade tool steel molds (H13, P20) consisting of fixed and movable halves. The stationary fixed half aligns with the injection
system, while the movable half integrates with the ejector mechanism. These precision-machined dies withstand 500-1200°C molten metal
temperatures and 10,000-100,000+ cycles. Material selection depends on production volume (prototype vs. mass production), alloy type
(Aluminum/Zinc/Magnesium), and part complexity (thin walls, tight tolerances).
