Die Casting​


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Materials Used For Die Casting​

Zinc Alloys
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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
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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
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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.

LET’S DO IT!

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Ready to Get a Die Casting Parts Quote? Free shipping available for domestic Die Casting Parts orders ; learn more!

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.

NameDescriptionMaterialsColorTexture
As CastRegular 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 materialsn/an/a
Powder CoatingPowder 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, SteelBlack, any RAL code or Pantone numberGloss or semi-gloss
Bead BlastingBead 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, Steeln/aMatte
AnodizingMainly 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.AluminumClear, black, grey, red, blue, goldSmooth, matte finish
Electro PhoresisUsed 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 SteelAnyMetallic luster
ElectroplatingElectroplating 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 Steeln/aSmooth, glossy finish
BrushingBrushing 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, Steeln/aSatin
 

 

Die Casting Parts Made By BOYI

Die Casting Technical Guidelines

DimensionStandards
Minimum part weight0.017 kg
Maximum part weight12 kg
Minimum part size∅ 17 mm × 4 mm
Maximum part size300 mm × 650 mm
Minimum wall thickness0.8 mm
Maximum wall thickness12.7 mm
Quality ControlISO 9001 Certified
Minimum possible batch1000 pcs

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FAQs

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.

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.

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.

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.

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.

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.

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.

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.

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Testimonials

See What Our Customers Say

"BOYI has consistently impressed us with their precision in manufacturing custom OEM components. From the intricate details to the overall quality, they have exceeded our expectations. The attention to detail in their production process ensures that each part meets our specifications, contributing to the success of our final products. It's not just about getting the job done; it's about getting it done right, and BOYI has consistently delivered on that front."

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Ishita Malhotra

Supply Chain Director at Precision Dynamics

"Working with BOYI has been a game-changer for our production timelines. The team's commitment to delivering on time is unmatched. In the fast-paced world of OEM manufacturing, meeting deadlines is crucial, and BOYI has proven time and again that they not only understand the urgency but also have the capability to deliver high-quality custom components within the specified timeframes. Their reliability is a key factor in our continued partnership."

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Kylo James

Engineering Manager at TechInnovate Corp

"BOYI stands out as more than just a supplier; they are collaborative problem solvers. In the course of our projects, challenges inevitably arise, and BOYI has consistently demonstrated a proactive approach in finding solutions. Their engineering team engages with ours, providing valuable insights and recommendations to optimize designs for manufacturability. This collaborative spirit has not only streamlined our production processes but has also strengthened our product offerings."

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Ella Perez

Procurement Manager at NexGen Innovations

"BOYI has been instrumental in our cost-effective OEM customization journey. Their ability to provide tailored solutions without compromising quality has significantly impacted our bottom line. The transparent communication regarding costs and the flexibility in adapting to our evolving needs have made them a trusted partner. BOYI doesn't just offer manufacturing services; they offer a strategic partnership that adds value to our entire product development lifecycle."

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Elsie Ross

R&D Lead at InnovateTech Solutions

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