Die Casting 101 / FAQ

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.

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.