What is Die Casting?
Die casting is a similar process to injection molding, and it is a metal casting technique that involves pressing molten metal into a mold cavity to manufacture metal components. At HLH, we use certified machines and die-casting molds to form your design from molten metal (usually zinc, copper, aluminum, magnesium, lead, tin, or other tin-based alloys). Our die-casting process is efficient and highly reliable, and it can significantly reduce costs. Due to our flexibility, we can meet any project requirements of yours - from small batches of 50 pieces to up to 1,000 pieces.
Our Die Casting Processes Services
Hot-Chamber Die Casting
Hot chamber die casting is a metal casting process specifically designed for low-melting-point alloys such as zinc, tin, lead and magnesium. This process is the most common and faster method compared to cold chamber die casting. In this method, the metal melts in a furnace connected to the machine within the casting machine. The hydraulic system injects the molten metal into the mold under high pressure. This process can effectively use high-quality materials with lower melting points to produce complex shapes.
Cold chamber die casting
Cold chamber die casting involves using a steel mold or pouring method to introduce molten metal at room temperature into a separate injection chamber. The injection chamber contains a ram that vertically pushes the molten metal into a steel mold (die) with movable and fixed parts. The ram exerts a pressure of 2,000 to 20,000 PSI, pushing the molten metal into the mold. The pressure is maintained until the metal cools and solidifies, and then the finished product is ejected from the mold. This method is suitable for high-melting-point alloys such as aluminum.
Advantages and drawbacks of Die casting
Fast cycle time.
Suitable for manufacturing complex parts.
Produces parts with high dimensional accuracy.
Produces smooth-surfaced parts, thereby reducing the need for post-processing.
Provides repeatable and accurate results through efficient production.
The cost of equipment and dies can be very expensive.
Is typically unsuitable for ferrous metals or metals with a high melting point.
Designing and tooling new dies is a complex process that can take long before a production run starts.
Up-front costs and lead times may be prohibitively high with small production batches.
Surface finishes
Surface finishes can serve either a functional or aesthetic purpose. Surface finishes that serve both purposes are deemed cosmetic finishes, and are used for cosmetic parts. Producing cosmetic parts requires additional measures to minimize defects such as hang marks and scratches from tools.
How to Work With Us
Upload a CAD File
To start, simply select a manufacturing process and upload a 3D CAD file.
Get Quote with DFM
Within a few hours we'll send you design for manufacturability (DFM) analysis and real-time pricing.
Manufacturing Begins
Once you review your quote and place your order, we'll start the manufacturing process. We also offer finishing options.
Parts are Shipped!
Our digital manufacturing process allows us to produce parts in as fast as 1 day.
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Die Casting Materials
Aluminum alloy
Aluminum alloys are widely used in the die-casting field due to their unique properties. Alloys such as 380, 360, 390 and 413 have high working temperatures, excellent corrosion resistance, low density, outstanding strength and good thermal conductivity. In addition, aluminum alloys also have good stiffness, a good strength-to-weight ratio, EMI and RFI shielding performance, and recyclability. They can also withstand high temperatures and maintain the dimensional stability of thin walls.
Zinc Alloys
Zinc alloys, including Zamak #2, #3, #5, #7, ZA8, and ZA27, offer a balance of strength, toughness, firmness, and cost-effectiveness. These alloys are known for their improved castability, shortened cycle time, and extended die life. The mechanical qualities of zinc alloys rival and exceed other common die-casting materials such as aluminum, magnesium, and bronze. Their exceptional casting fluidity contributes to thin-wall castability, resulting in smaller, lighter, cost-effective components.
Magnesium Alloys
Magnesium, particularly the AZ91D alloy, stands out for its toughness, durability, lightweight nature, and good castability. With a weight 75% lighter than steel and 33% lighter than aluminum without compromising strength, magnesium alloys are preferred for applications requiring complex casting with tight tolerances. The material’s excellent corrosion resistance further enhances its appeal.