What is Die Casting?
Die casting is the manufacturing process of choice when producing high volumes of relatively
complex metal parts and is widely used due to its versatility, reliability, and accuracy. Die
casting eliminates all or most secondary operations needed to make a metal part; however,
post-machining is common to meet tighter critical-to-function tolerances. Die casted parts can
also be post-processed in any finish their respective CNC machined counterparts can.
Like injection molding , die casting requires the fabrication of a mold tool–called a
die–that can have one or multiple cavities. The process works for softer alloys, including
aluminum and zinc alloys, due to their relatively lower melting temperature. Die casting works
by injecting molten metal into a die cavity, which takes the shape of the part and hardens
into place before removal. Depending on the project scope, die casting can be low- or
high-pressure, using a ladle or plunger to deposit metal. Die casting can produce highly
complex, tight-tolerance parts in a repeatable manner at very high production volumes. Modern
die casting methods such as squeeze casting and semi-solid metal casting produce high-quality
parts for nearly every industry. Die casting companies will often specialize in casting
aluminum or zinc, with aluminum making up roughly 80% of die cast parts.
Our Die Casting Processes Services
HLH partners with die casters utilizing the latest die casting machines and technologies to provide high-quality, on-demand parts for a wide range of industries. Our products focus on two main types of die casting: hot chamber casting and cold chamber casting. Both types can produce parts with complex geometries, precise tolerances, and robust mechanical properties.
Hot Chamber Die Casting
Also known as gooseneck casting, hot chamber die casting is the most popular die casting process. It is best suited for low-melting-point alloys such as zinc, magnesium, and lead. A holding vessel is filled with metal and heated using hot chamber die casting until it melts in a connected or built-in furnace. A feature of the hot chamber system, known as the gooseneck tube, is the formation of a holding chamber within the vessel and a nozzle-like channel that connects to the injection cavity in the fixed half of the mold. A plunger located above the chamber allows molten metal to be filled from the holding vessel. As the chamber is loaded, the plunger descends, forcing the molten material along the gooseneck tube into the mold cavity. As the metal cools and solidifies in the mold, the mold is held together under pressure. Once the metal has cooled sufficiently, the mold opens, and the casting is ejected by an ejector pin.
Cold Chamber Die Casting
Cold chamber die casting employs a process where the chamber is maintained at room temperature, without a heat-insulating vessel for the molten metal. The metal is melted in a separate furnace and manually deposited into the shot-peening chamber through a gating hole using a ladle. In cold chamber die casting, the mold is directly connected to the injection chamber, eliminating the use of a plunger system. Instead, a punch forces the molten metal into the mold and maintains high pressure as the metal solidifies. This type of die casting is suitable for materials with relatively high melting temperatures, such as aluminum.
Advantages of Die casting
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Complex Geometry
Die casting allows for the creation of complex shapes and intricate designs that may be difficult or impossible to achieve with other manufacturing methods.
Strength
Metal die castings are typically stronger than plastic injection molded parts and more resistant to high temperatures. Metals such as aluminum offer exceptional strength-to-weight ratios.
Precision
Die casting offers typical tolerances ranging from +/-0.003″ – 0.005″ per inch but can go as tight as +/- .001” depending on your specifications, part geometry, and material.
Custom Finishes
Metal finishers can produce cast parts with smooth or textured surfaces, paints, and plating finishes. Finishes can protect from corrosion and improve cosmetic appearance.
Die Casting Materials
Metal Materials for Die Cast Parts
Several different metal materials are available to choose from when manufacturing using die
casting. The material you choose will depend on your intended use for the product. For
instance, cast aluminum parts are common in aerospace or automotive applications where
corrosion resistance and weight reduction are essential factors. You can learn more about
the main types of die casting materials we offer in the sections below. If you have a
specific material request, just let us know!
Aluminum alloys are the most widely used for die cast parts. Aluminum die casting suppliers
benefit from the total recyclability of the material and its ease of use. Due to the
comparatively higher melting point, aluminum die casting may require a cold chamber casting
process. Engineers use cast aluminum parts primarily for their great strength to weight
ratios, dimensional stability, and diverse finishing options.
Zinc is the easiest to cast material among the die casting metals and is typically used in
hot chamber processes. Molten zinc has exceptional casting fluidity and a lower melting
point. Its strength and stiffness allow it to produce parts with thinner walls and highly
detailed features and maintain tight tolerances. The low melting point of die casting zinc
alloys means the zinc die cast components cool off and solidify more quickly, which results
in the fastest production rates of the die casting materials.
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What it’s like to work with HLH – in our customers’ words
"It is a pleasure to work with a company whose personnel are willing and able to think out of their box. With your commitment to staying on the cutting edge of technology, you supply tooling to us that is right on time and works first shot."
"Not many other manufacturing facilities would prioritize a job with a volume this low. They treated us as if we were a long-time customer bringing in high-volume business."
“HLH has been a strong partner on our EV programs. They helped us optimize a few key mponents for weight and manufacturability, and they consistently hit the tolerances we need. Their fast turnaround times have kept our development cycles moving, which is critical in EV work.”
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