Die Casting 101 / FAQ

Die casting is a manufacturing process that uses high pressure to inject liquid metal into a reusable steel die. Rapid cooling solidifies the metal into a final shape.

The basis for the die casting process is using high pressures to inject liquid metal into a reusable steel die. There are some variations to the process, such as: hot chamber die casting, cold chamber die casting, structural (or high integrity) die casting.

High Speed Production – Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and hundreds of thousands of identical castings can be produced before additional tooling is required.

Dimensional Accuracy and Stability – Die casting produces parts that are dimensionally stable and durable, while maintaining close tolerances. Castings are also heat resistant.

Strength and Weight – The die casting process is suited for thin wall parts, which reduce the weight, while maintaining strength. Also, die casting can incorporate multiple components into one casting, eliminating the need for joining or fasteners. This means that the strength is that of the alloy rather than the joining process.

Multiple Finishing Techniques – Die cast parts can be produced with a smooth or textured surface, and they are easily plated or finished with minimum or surface preparation.

Simplified Assembly – Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.

	Sand	Permanent	Die
	Casting	Mold	Casting
Dimensional Accuracy	Good	Better	Best
Wall Thicknesses	Thickest	Medium	Thinnest
Surface Finish	Average	Better	Best
Typical Size Range	Medium to Very Large	Small to Very Large	Small to Large
Cycle Times	Slowest	Medium	Fastest
Production Volumes	Low	Medium	High
Tool Cost	Lowest	Medium	Highest
Tool Construction Lead time	Lowest	Medium	Highest
Unit Cost	Highest	Medium	Lowest

Die castings are used in every industry. Some of the industries that use large numbers of die castings are:

• Automotive - EV and ICE
• Commercial Vehicle
• Recreational Vehicle
• Industrial Components
• Builder's Hardware
• Lawn & Garden
• Lighting
• Telecommunications
• Power & Hand Tools

• Wall Thickness – Die castings benefit from a uniform wall thickness.
• Draft – Sufficient draft is required to extract the casting from the die.
• Fillets – All edges and corners should have a fillet/radius.