Precision die casting is a high-precision, high-efficiency metal forming manufacturing process that injects molten non-ferrous alloy under extreme high pressure into precision-machined hardened steel dies. It produces near-net-shape metal components with ultra-tight dimensional tolerances, exceptional surface smoothness, minimal post-processing requirements, and consistent repeatability for mass production.
Tolerance: ±0.003 mm
Thin Wall: Down to 0.3 mm
Surface Finish: Ra ≤0.8 μm
Casting Type: High-Pressure Non-Ferrous
01. Applicable Raw Materials
Non-Ferrous Metals Only
Aluminum Alloys
A380, A413, ADC10, ADC12 Most widely used. Delivers lightweight, high strength, and excellent corrosion resistance for structural parts.
AZ91D, AM60 Ultra-lightweight metal tailored for automotive electronics, drones, and aerospace hardware.
Copper/Brass Alloys
Precision Castings Specialized applications for electrical fittings requiring superior electrical conductivity.
Note on Compatibility: Ferrous metals (steel, iron) are not compatible, as their high melting temperatures rapidly degrade precision hardened steel molds.
02. Core Equipment & Tooling System
1. Die Casting Machines
Cold-Chamber Units: Designed for Aluminum & Magnesium alloys; molten metal is ladled separately under high pressure.
Hot-Chamber Units: Designed for Zinc alloys; submerged injection plunger delivers rapid cycle times for small parts.
Digital Control: Real-time monitoring of injection velocity, boost pressure, and clamping force to eliminate dimensional drift.
2. Precision Mold Dies
Steel Substrates: H13, SKD61, STAVAX tool steel (48–52 HRC) to withstand thermal fatigue and deformation.
Cavity Machining: CNC 5-axis milling, wire EDM, and mirror polishing to achieve cavity roughness Ra 0.02–0.8 μm.
Micron Accuracy: Mold cavity dimensions held to ±0.002 mm with built-in temperature control channels.
3. Auxiliary Systems
Vacuum Systems: Pulls air out of mold cavity to eliminate internal porosity, bubbles, and surface blisters.
Mold Temp Controllers: Maintains surface temperature (±1°C) to prevent warpage and uneven cooling.
Automated Robotics: Robotic extractors, automated trimming presses, and CMM 3D metrology inspection tools.
03. Manufacturing Workflow
STEP 01
Mold Preheating
Preheated via oil/water; release agent sprayed uniformly.
STEP 02
Alloy Melting
Melted and held in narrow window (±5°C).
STEP 03
Vacuum Seal
High-tonnage clamping & immediate air evacuation.
STEP 04
3-Stage Injection
Slow fill, high-speed shot, and intensification boost.
