Die Casting

 A faster, easier way to order high-quality Die Casting parts that accelerates iteration, testing, and scaled production. Upload your designs for feedback and pricing in 1 business day.

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Materials Used For Die Casting

Zinc Alloys

1. Precision & Detail: Zinc alloy die casting allows for high-precision components with intricate details.
2. High Strength: Zinc die-cast parts offer exceptional durability and resistance to wear.
3. Ease of Casting: Zinc’s fluidity makes it ideal for die casting, ensuring smooth and defect-free components.
4. Extended Lifespan: Zinc alloy die-cast parts are resistant to environmental impacts, ensuring a longer product life.
5. Cost-Effective Finishing: Zinc die casting achieves a smooth finish, reducing post-processing costs.

Aluminum Alloys

1. Lightweight & Strong: Aluminum die casting delivers robust components without added weight.
2. Corrosion Resistance: Aluminum die-cast parts naturally withstand corrosion, ensuring longevity.
3. Malleability: Aluminum’s adaptability allows for intricate die-cast designs.
4. Cost-Effective: Aluminum’s abundance makes die casting more affordable.
5. Thermal Conductivity: Aluminum die casting excels in heat dissipation, ideal for heat-sensitive components.

Magnesium Alloys

1. Ultra-Lightweight: Magnesium alloy die casting produces the lightest metal components, ideal for weight-sensitive applications.
2. High Strength-to-Weight Ratio: Despite its lightness, magnesium die-cast parts maintain impressive strength, ensuring durability.
3. Excellent Damping Capacity: Magnesium alloys absorb vibrations, making die-cast parts ideal for noise and vibration reduction.
4. Rapid Production: Magnesium’s properties allow for faster die casting cycles, leading to quicker production times.
5. Eco-Friendly: Magnesium die casting is recyclable and requires less energy in production, supporting sustainable manufacturing.

Die Casting Overview

Die casting emerges as the preferred manufacturing process for high-volume production of intricate metal components, valued for its versatility, reliability, and precision. Widely adopted, this method eliminates or minimizes the need for secondary operations in metal part production. Although post-machining may be employed to achieve tighter critical-to-function tolerances, die casting often obviates the necessity for additional processes.

Similar to injection molding, die casting involves the creation of a mold tool, referred to as a die, with the capability of accommodating one or multiple cavities. Suited for softer alloys such as aluminum and zinc due to their lower melting temperatures, die casting employs the injection of molten metal into a die cavity, solidifying into the desired shape before extraction. The process can be either low- or high-pressure, utilizing a ladle or plunger to deposit the molten metal.

Die casting excels in producing intricately designed, tight-tolerance parts consistently and efficiently, making it ideal for high-volume production. Modern techniques like squeeze casting and semi-solid metal casting further enhance the quality of components across diverse industries. Die casting companies often specialize in aluminum or zinc casting, with aluminum constituting approximately 80% of die-cast parts.

At our facility, each die casting project undergoes personalized scrutiny from our project managers and experts, ensuring a tailored approach to meet your unique requirements. Our commitment to a swift and seamless manufacturing experience is reflected in our thorough review and manual quoting processes. Explore more about the die casting process and our capabilities in the sections below.

Die Casting Types Available from

BOYI partners with die casters that utilize the latest die casting machines and technology to deliver high-quality, on-demand parts to a wide variety of industries. Our offering focuses on the two leading types of die casting: hot chamber casting and cold chamber casting. Both types can produce parts with complex geometry, close tolerances, and robust mechanical properties.

Hot Chamber Die Casting

Hot Chamber Die Casting, also known as gooseneck casting, stands as the preferred die casting method and finds its optimal application with lower melting point alloys like zinc, magnesium, and lead. In this process, a holding pot is loaded with metal and heated until molten by an attached or built-in furnace. The distinctive gooseneck feature forms a holding chamber within the pot, creating a nozzle-like pathway connecting to the injection cavity of the fixed die’s half. Positioned above the chamber, a plunger allows molten metal to fill the chamber from the holding pot. Subsequently, the plunger lowers, compelling molten material up the gooseneck into the die cavity. While the metal cools and solidifies in the mold under pressure, the dies remain closed. Once the metal reaches an adequate temperature, the dies open, and the casted piece is ejected through ejector pins.

Cold Chamber Die Casting

Cold Chamber Die Casting, in contrast, maintains the chamber at room temperature and lacks a holding pot of molten metal. Metal is melted in a separate furnace and manually poured into the shot chamber through a ladle. In the cold chamber die casting process, the mold directly connects to the shot chamber, eliminating the need for a plunger system. Instead, a ram applies pressure to force molten metal into the mold, holding it under high pressure until solidification. This die casting method is particularly suitable for materials with comparatively higher melting temperatures, such as aluminum.

How to work with us

1.Sending CAD Files To Email or LinkedIn

First, you can send CAD files and detailed information (material, quan-tity, tolerance, etc.) to us Email or Linkedin .

2.Manufacturability Analysisand Offering Quotation

Secondly, we will analyze manufactur-ability based on drawings of productsand give you a favorable quotation.

3.Start manufacturing!

Thirdly, we will start manufacturing process once all relevant deatials are fully confirmed.

4.Parts are Completedand Shipped

Finally, we will carefully pack and shipthe goods when the products are completed.

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Die Casting Surface Finishes

Post-processing and finishing represent the conclusive phase of precision die casting. This stage involves the application of finishing techniques to eliminate surface defects in cast parts, enhance mechanical or chemical properties, and elevate the cosmetic appearance of products. Six die casting surface finish options are available for consideration.

Name	Description	Materials	Color	Texture
As Cast	Regular casting finish obtained without the use of high-end tools or machinery. Like Zinc and Aluminum-Zinc parts can be as cast but still keep high corrosion resistance.	All materials	n/a	n/a
Powder Coating	Powder Coating can be used to spray a free-flowing, dry powder to the zinc alloy and aluminum alloy die casting. Under strong electrostatic and high temperature, the powder will be uniformly adsorbed on the surface of the casting, forming a powder layer that can mask defects very well.	Aluminum, Stainless Steel, Steel	Black, any RAL code or Pantone number	Gloss or semi-gloss
Bead Blasting	Bead Blasting is a process that sprays fine glass beads at high speed onto the surface of die casting parts using compressed air as the powder. The appearance or shape is changed, and the part obtains excellent cleaning and surface preparation for secondary finishing operations.	ABS, Aluminum, Brass, Stainless Steel, Steel	n/a	Matte
Anodizing	Mainly for aluminum alloy die casting. Anodizing utilizes electrochemical principles to generate a layer of Al2O3 (aluminum oxide) film on the surface of the parts. This decorative layer of oxide film provides high insulation and wear resistance.	Aluminum	Clear, black, grey, red, blue, gold	Smooth, matte finish
Electro Phoresis	Used for aluminum alloy, zinc alloy die casting, etc. Electrophoresis applies metallic luster and an unlimited range of colors on the casting parts. It also can enhance the surface properties and corrosion resistance of metal alloy parts.	Aluminum, Zinc, Stainless Steel	Any	Metallic luster
Electroplating	Electroplating can be functional, decorative or corrosion-related. Many industries use the process, including the automotive sector, in which chrome-plating of steel automobile parts is common.	Aluminum, Steel, Stainless Steel	n/a	Smooth, glossy finish
Brushing	Brushing is a surface treatment process in which abrasive belts are used to draw traces on the surface of a material, usually for aesthetic purposes.	ABS, Aluminum, Brass, Stainless Steel, Steel	n/a	Satin

Die Casting Technical Guidelines

Dimension	Standards
Minimum part weight	0.017 kg
Maximum part weight	12 kg
Minimum part size	∅ 17 mm × 4 mm
Maximum part size	300 mm × 650 mm
Minimum wall thickness	0.8 mm
Maximum wall thickness	12.7 mm
Quality Control	ISO 9001 Certified
Minimum possible batch	1000 pcs

A Quick Guide To Designing Die Casting Parts

In this guide, we will delve into essential design principles and guidelines aimed at optimizing outcomes for your die casting endeavors.

1. Fillets and Radii: Enhancing Strength and Aesthetics

In die casting, one of the most crucial design aspects is the incorporation of fillets and radii. These features facilitate smooth transitions between surfaces, alleviating stress concentrations and ensuring the final product’s strength, aesthetics, and durability.

2. Wall Thickness: Balancing Strength and Weight

The wall thickness of die cast parts must be meticulously designed to achieve the desired strength, stiffness, and weight. It influences cooling time, pressure exertion on the mold, and overall part integrity, with optimal thickness varying based on factors like part size, material, and production process.

3. Ribs and External Corners: Reinforcing Structural Integrity

Ribs enhance component stiffness and load distribution while preventing warping, while external corners contribute to aesthetic appeal. Careful consideration of their thickness and spacing is essential to avoid stress concentrations and ensure optimal performance.

4. Windows and Holes: Maintaining Integrity and Functionality

Windows and holes in die castings facilitate fluid passage and assembly connections. Their design should prioritize rounded edges, strategic placement, and appropriate draft angles to preserve part strength and ease of manufacture.

5. Post Machine Features: Optimizing Post-Casting Processes

Certain features, like threads or undercuts, may require post-machining. Designing for post-machining involves considering feature location, machinability, and achievable tolerances to minimize additional production time and cost.

6. Parting Lines: Minimizing Visual Impact

The location and thickness of the parting line, where mold halves meet, influence the final product’s appearance and integrity. Careful design considerations aim to reduce seam visibility, prevent part shattering, and manage flash formation during ejection.

7. Surface Finishing Grades: Enhancing Aesthetics and Functionality

After casting, surface finishing is crucial to meet application-specific requirements. Surface finishing grades, ranging from utility to superior, determine the final appearance and functionality of die cast parts, aligning with intended market segments and quality standards.

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FAQs

What Defines the Precision Die Casting Process?

The precision die casting process involves injecting molten metal into a reusable mold cavity at high pressure, ensuring intricate and accurate details in the final product. This method is widely used for complex geometries, tight tolerances, and high-volume production.

How is Consistent Metal Parts Production Ensured by Die Casting Machines?

Die casting machines maintain consistent metal parts production through precise control of factors such as temperature, pressure, and injection speed. Automation and advanced monitoring systems contribute to the reliability and repeatability of the process.

In What Ways Does Aluminum Die Casting Stand Apart from Sand Casting?

Aluminum die casting differs from sand casting in its efficiency, speed, and ability to produce intricate and lightweight parts. The die casting process ensures better surface finish and dimensional accuracy compared to sand casting.

Which Offers Greater Durability: Die Casting or Plastic Injection Molding?

Die casting surpasses plastic injection molding in durability due to the use of metal alloys, providing superior strength, heat resistance, and dimensional stability. This makes die-cast parts ideal for applications requiring robustness and precision.

Why is Aluminum Alloy the Preferred Choice in the Die Casting Industry?

Aluminum alloy is favored in die casting for its lightweight properties, excellent thermal conductivity, and corrosion resistance. These attributes make it a preferred choice for various industries, including automotive, aerospace, and consumer electronics.

What Constraints Exist in the Die Casting Technique?

Limitations of die casting include challenges with large part sizes, high tooling costs, and limitations in material choices. Additionally, achieving thin wall sections and uniform cooling can pose challenges in certain designs.

How Do Die Casting Alloys Such as Zinc and Magnesium Shape Product Quality?

Die casting alloys, such as zinc and magnesium, influence product quality by offering specific mechanical properties, corrosion resistance, and thermal conductivity. Proper alloy selection is crucial for meeting the performance requirements of the final product.

Which Industries Frequently Embrace the Metal Casting Process?

Industries frequently employing the metal casting process include automotive for engine components, aerospace for lightweight structural parts, electronics for housing and heat sinks, and telecommunications for durable and conductive components. Other sectors include medical equipment, industrial machinery, and consumer goods.

Exploring Die Casting Services: Applications Across Industries

Die casting is a versatile manufacturing process that finds applications across various industries due to its ability to produce complex shapes with high precision and efficiency. Let’s delve into some key industries where die casting services play a pivotal role in producing quality components.

Automotive Industry

In the automotive sector, die casting is extensively used for manufacturing engine parts, transmission components, and structural elements. The process allows for the creation of lightweight yet durable parts, contributing to fuel efficiency and overall vehicle performance. Die-cast aluminum and zinc alloys are commonly employed due to their excellent strength-to-weight ratio and corrosion resistance, making them ideal for automotive applications.

Electronics and Electrical Appliances

Die casting plays a crucial role in the production of electronic enclosures, heat sinks, and connector housings. The process enables the creation of intricate designs with tight tolerances, essential for housing sensitive electronic components. Aluminum and magnesium alloys are favored for their thermal conductivity and electrical properties, ensuring optimal performance and durability in electronic devices and appliances.

Consumer Goods

Die casting is widely utilized in the manufacturing of consumer goods such as furniture hardware, kitchenware, and decorative items. The process allows for the mass production of intricate designs with consistent quality, meeting the demands of the consumer market. Aluminum and zinc alloys are preferred for their aesthetic appeal, corrosion resistance, and ease of finishing, making them suitable for a wide range of consumer applications.

Aerospace and Defense

In the aerospace and defense sectors, die casting is employed for producing components that require high strength, precision, and reliability. Aircraft and defense equipment often incorporate die-cast parts such as structural components, brackets, and housings. Aluminum, magnesium, and titanium alloys are commonly used for their lightweight properties and high strength-to-weight ratio, contributing to the overall performance and safety of aerospace and defense systems.

Industrial Machinery

Die casting finds extensive use in the manufacturing of industrial machinery components such as gears, housings, and hydraulic parts. The process enables the production of parts with complex geometries and tight tolerances, essential for ensuring smooth operation and reliability in industrial applications. Aluminum, zinc, and brass alloys are commonly employed for their strength, durability, and machinability, meeting the rigorous demands of industrial machinery.

Die Casting​

A faster, easier way to order high-quality Die Casting​ parts that accelerates iteration, testing, and scaled production. Upload your designs for feedback and pricing in 1 business day.