Custom Die Casting Service
Moldpartner makes high-quality die casting parts. We use advanced pressure die-casting technology for precision components. Our one-stop service covers aluminum, zinc, magnesium, and copper alloys, providing tight tolerances, complex geometries, and superior surface finishes for industries such as automotive, aerospace, and electric vehicles.
- Precision Die Casting Machining
- Supports complex shapes and high precision
- Small to medium batch production
- Excellent surface finish and detail
Die Casting Materials
Our primary die casting materials include aluminum, zinc, magnesium, and copper. Each material was selected for its unique properties and advantages in it’s applications.
Aluminum Die Casting
Aluminum is lightweight yet strong, making it suitable for applications with extremely high durability and lightweighting requirements, such as the automotive and aerospace industries.
- Aluminum ADC12, ADC6, A360, A38
Zinc Die Casting
Zinc is tough, which means it can be cast with high precision and tolerance. This allows for the creation of complex designs and strong components.
- Zinc Zamak 3, Zamak 5, Zamak 2, ZA8
Magnesium Die Casting
Magnesium is the lightest structural metal. It has a great stiffness-to-weight ratio. This makes it perfect for applications where weight matters.
- Magnesium AZ91D, AM60B
Copper Die Casting
Copper has excellent thermal and electrical conductivity, making it ideal for use in heat sinks and electrical connectors.
- Copper ZQA19-2, ZQA19-4, ZQA19-7, ZQA19-10
What is Die Casting?
Die casting is a process that shapes metal parts. It’s similar to injection molding. Molten metal is forced into a mold cavity at high pressure to create precise shapes. At Moldpartner, we use certified equipment and professional die casting molds to transform metal raw materials such as zinc, copper, aluminum, magnesium, lead, and tin-based alloys into your designed products. Our die casting process combines high efficiency and reliability, significantly optimizing production costs. We provide flexible capacity options. This means we can customize solutions for small-batch pilot production of 50 pieces and medium-batch needs of 1,000 pieces.
Very low cost per part in high-volume production.
Excellent surface finish and outstanding dimensional stability.
Capable of producing complex geometries with little or no secondary machining required.
Highly efficient for producing medium and large parts in volume, offering significant time and cost savings over machining.
Advantages of Die Casting
In the first part, our die-casting offerings are robust and affordable. The advantages of metal die casting are:
Parts produced by die casting are stronger, more rigid, and longer-lasting than those made by other techniques.
Mold designs can have assembly features such as holes, bosses, and snap fits. This helps minimize the need for extra machining or processing later.
The high pressure in die casting enables it to capture critical details and achieve tight tolerances. It can also produce parts with thin walls and high dimensional accuracy, for instance, where a part is crucial to performance and functionality.
Die casting can capture even the most intricate design details in a mold and use pressure to transfer them into the part. The surface finish of castings is near-perfect post-production, but can be further improved with custom finish options.
Die casting is the most cost-effective method for producing large volumes of finished metal parts for mass production. The high-quality tooling involved also ensures that any unit of parts, from thousands to millions, can be economically made before replacement is required. Consequently, it will achieve a lower cost-per-unit in mass production. The uniformity of mass-produced die-cast parts is exceptional.
Die casting works well for making larger metal parts. It’s faster and cheaper than CNC machining for these items. It has average cycle times of 2 to 60 seconds. This makes it a fast option for projects needing quick turnaround and lead times.
Die casting operations can achieve complex shapes and geometries, and parts with thin walls seamlessly, with little or no need for post-machining on ejection.
Aluminum extrusions can be finished in many ways. This customization helps optimize your part’s functionality and meet your product needs. You can create pieces to your exact specifications.
Die Casting Process
High pressure is the core step in the die-casting process, where molten metal is injected into the mold. The specific process is as follows:
01
Create A Mold
The first step in mold manufacturing is using computer-aided design (CAD). This helps create a detailed 3D model. It outlines important features such as the parting line, gating system, and cooling channels. After design completion, we use precision equipment such as CNC milling machines and electrical discharge machining (EDM) to machine high-quality mold steel, ensuring micron-level precision. Subsequently, the heat treatment process improved the mold’s hardness and wear resistance. Finally, polishing, assembly, and trial molding verification ensure the mold can consistently produce qualified parts.
02
Clamping Process
Clamping is the process of closing and locking the mold under high pressure. The mold surface must be cleaned and lubricated before operation. This is done to prevent impurities from affecting the quality of the parts and to facilitate smooth demolding. After preparation, the hydraulic or mechanical system precisely aligns and closes the mold, applying a controlled and uniform force. Simply put, this force must be large enough to withstand the enormous pressure generated during the subsequent injection of molten metal, preventing flash or mold misalignment. This ensures mold structural stability during metal filling and solidification. This step is crucial for ensuring dimensional accuracy and preventing defects.
03
Casting
The core of the casting stage is injecting molten metal into the injection chamber, and then using high-pressure hydraulic pressure to fill it rapidly into the mold cavity. Depending on the equipment, this process is divided into cold chamber and hot chamber methods. High pressure is crucial here; it ensures that the molten metal fills every complex corner, reduces internal porosity, and perfectly replicates the mold’s fine shape. We precisely control the injection speed and pressure through a hydraulic system to avoid turbulence while ensuring dimensional accuracy of the parts.
Cooling
The cooling phase is vital for die-cast parts. It affects their structural strength, size accuracy, and surface finish. After molten metal is injected, controlled cooling methods are needed to ensure uniform solidification within the mold cavity. We choose forced cooling or natural cooling based on the part’s size, shape, and material. For complex parts, we also employ advanced temperature control systems such as conformal cooling to ensure synchronous and uniform solidification across all areas. This effectively reduces defects such as porosity, deformation, and shrinkage marks, improving product mechanical properties while shortening the production cycle.
Ejection
Once the casting has cooled and solidified in the mold, the ejector pins, driven by a mechanism, smoothly push the part out of the cavity. This process requires precise control of force and timing. Therefore, accurate ejection is crucial to ensuring the part does not deform, tear, or suffer surface damage, and is also an important part of maintaining a stable and efficient production rhythm.
Trimming
After the casting is removed from the mold, it still carries excess material such as gates, runners, sprues, and flash. Depending on the product requirements, we use different precision methods, such as mechanical trimming presses, CNC machining, or robotic cutting, to remove these excess parts. This step ensures more accurate part dimensions, a cleaner appearance, and no impact on functionality. The cut-off material can also be recycled, meeting the requirements of green production. To protect the casting from damage during trimming, we typically use custom-made fixtures and precisely control the trimming force to ensure that the part is cleaned while maintaining its surface and structure intact.
Finishing Options for Die Casting Services
| Images | Name | Descriptions |
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Anodizing | Anodizing is a process that uses an electric current to form a layer of aluminum oxide on aluminum surfaces. This process can improve the corrosion resistance, wear resistance, and hardness of materials, and provides a wide range of color options. At the same time, it imparts good thermal stability and insulation to the surface, making it ideal for high-end fields such as aerospace, automotive, and consumer electronics. |
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As the machined or deburring | Machining/deburring is a finishing process. It uses specialized tools to eliminate burrs and create chamfers. This results in a smooth surface, typically with a roughness of Ra = 3.2 μm. This process ensures the parts work well, are safe, and fit with later coatings or assemblies. |
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Bead Blasted | Bead blasting uses propelling fine spherical media to hit a workpiece. It creates a uniform matte surface that effectively hides tool marks and small defects. This method not only improves the aesthetics but also provides a better adhesion foundation for subsequent painting, electroplating, and other processes. It is suitable for various engineering plastics such as aluminum, stainless steel, brass, steel, and ABS, and does not alter the critical dimensions of the parts. |
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Powder coating | Powder coating is a surface treatment process. It utilizes the deposition of dried thermosetting polymer powder and high-temperature curing to form a robust coating. This coating is very durable. It resists peeling, scratches, chemical corrosion, and UV radiation well. At the same time, this environmentally friendly coating (zero VOC) maintains long-lasting vibrant colors, offers rich textures, and combines aesthetic appeal with functional protection. |
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Polishing | Polishing is a method that uses abrasives to make a metal surface smooth and shiny. This processenhances the aesthetics and light reflectivity of parts. Their size and structure stay unchanged. |
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Brushing | The brushing process uses an abrasive brush or polishing pad to create a uniform, unidirectional satin texture on the metal surface. This process can improve the appearance and cover up minor imperfections. Furthermore, this surface is more resistant to everyday scratches and less prone to fingerprints. |
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Smooth machining | Smoothing machining is a method that obtains a smooth surface quality by precisely controlling parameters such as feed rate, cutting speed, and tool angle. It significantly reduces visible tool marks, controlling surface roughness to Ra 1.6 micrometers or even lower. Due to fewer microscopic defects, it is less prone to moisture and contaminant accumulation, thus simultaneously improving the corrosion resistance of the parts. |
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Black-Oxide | Black oxide is a process that creates a black magnetic oxide film on a metal surface through a chemical reaction. This film provides a matte appearance, basic rust protection and wear resistance, without altering the part's dimensions. It’s often enhanced with oil or wax seals for improved performance. This is popular for parts that need to be both functional and visually appealing. |
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Electro-less Nickel Plating | Electroless nickel plating is a chemical deposition process that does not require an external electric current to form a uniform nickel-phosphorus/nickel-boron alloy layer on the surface of a part using a chemical solution. This plating layer is very hard. It offers great wear and corrosion resistance. For example, high-phosphorus alloys can last over 5000 hours in salt spray tests. It has a uniform thickness, giving a semi-gloss to gloss finish. This ensures reliable chemical protection for complex parts. |
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Alodine | The Alodine is a process that creates a chromate conversion film on the aluminum surface, giving it a unique greenish-gold iridescence. This thin, corrosion-resistant film maintains the dimensions and conductivity of the part and improves paint adhesion. Therefore, it is a cost-effective surface treatment method suitable for mass production. |
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Electroplating | Electroplating is a process that deposits metallic coatings, such as chromium, nickel, and zinc, onto a metal substrate (steel or aluminum) by electrolysis. The barrier blocks moisture and chemicals. This boosts the corrosion resistance of parts and helps them last longer. |
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Nickel plating | Electroplating or electroless nickel plating deposits a thin layer of nickel on a metal surface. This plating resists corrosion and wear. It also looks good, ensures even coverage, and enhances conductivity. It is widely applicable to various functional and decorative applications in industries such as automotive, aerospace, electronics, and medical. |
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Passivation | Passivation is a chemical treatment. It enhances steel's corrosion resistance by forming a protective oxide layer. This process gets rid of surface contaminants, including free iron particles. It strengthens durability and makes the appearance more consistent. Plus, it doesn’t alter dimensions or function. |
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Yellow Chromate conversion coating | Yellow chromate conversion coating is a chemical process that creates a golden-yellow protective film on the surfaces of aluminum, magnesium, and zinc alloys. This film significantly improves corrosion resistance, maintains conductivity, and enhances paint adhesion. It is widely used in functional components in the aerospace, automotive, and electronics industries, and meets multiple environmental standards of MIL-DTL-5541. When using trivalent chromium formulations, it also complies with the RoHS directive. |
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PTFE (Teflon) Coating | Teflon coating offers great non-stick properties and a low friction level. It works well in temperatures from -200°C to +260°C. Plus, it resists corrosion by forming a PTFE layer on the surface. It's perfect for high-performance applications in automotive, aerospace, medical, and food processing. It boosts durability, whether made of metal, plastic, or composite. Plus, it makes daily cleaning and maintenance easier. |
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Fine machining | In simple terms, fine machining involves using high-precision equipment and finely ground tools. It helps control cutting factors like feed rate, cutting speed, and depth. This way, you get an excellent surface quality. It minimizes tool marks and other surface imperfections, consistently achieving a surface roughness of Ra 0.8 micrometers or even lower. While ensuring the dimensional accuracy and structural integrity of critical parts, it also delivers a very smooth, delicate surface finish. |
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Laser Cladding | Laser cladding is an advanced surface technology that uses lasers to achieve a metallurgical bond between the coating and the substrate. This technology can precisely repair part defects, restore dimensions, and form a dense, corrosion-resistant, and wear-resistant coating. It can precisely repair surface defects such as porosity, microcracks, and corrosion, and restore part dimensions. The heat input in this process is highly concentrated, minimizing part deformation, ensuring high precision, and it is applicable to a variety of materials. This technology is widely used in industries such as aerospace, automotive, energy, and mold making. |
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Sanding | Sanding is a mechanical surface treatment method that uses abrasives, such as sandpaper and grinding wheels, to polish the surfaces of parts. Its effects can be adjusted from matte to glossy, but it has limitations, such as rounding sharp corners and difficulty handling complex, intricate structures. But it has limitations, such as rounding sharp corners and difficulty handling complex, intricate structures. |
Applications
- We deliver ADAS housings (for cameras, radars, and lidars) that ensure compliance with VDA 19 standards.
- Meets VDA 19 standards for cleanliness and surface finish in ECU housings. This is done through automated deburring and porosity control.
- Transmission valve die casting, machining, leakage test development, and 100% leak test capability.
- Lightweighting applications for electric vehicles, such as battery component housings.
- Thin-wall applications through optimizing mold design and fabrication.
How To Work With Us
01
Request Instant Quote
When we receive your request, wewill quote for you within 24hours to get production started.
02
DFM Report
Die casting DFM optimizes part design for manufacturability, incorporating uniform wall thickness, draft angles, and fillets to ensure quality, reduce cost, and extend mold life.
03
Mold Flow Analysis
Die casting mold flow analysis uses simulation software to predict molten metal behavior during mold filling, optimizing gate design and preventing defects to ensure quality and efficiency.
04
Die Maker
We utilize advanced CNC machining centers, Mirror EDM, and precision wire-cutting equipment to manufacture close-tolerance mold components. Then assemble the die.
05
T1 samples Inspection
When the mold was finished, we started to produce Ti samples to send to customers to confirm.
06
Mass Production
After the trial production phase, we start mass production to produce parts quickly to save time and cost.
07
Strict Inspection
Our quality inspector will test the appearance, result, color, and assembly fit of the product.
08
Delivery
We cooperate with logistics companies to deliver goods to your destination quickly and safely.
Moldpartner Die CastingCapabilities
Moldpartner’s production capacity is detailed in the table below, with a focus on key performance and quality metrics.
| Description | |
| Minimum Part Weight | 0.017 kg |
| Maximum Part Weight | 12 kg |
| Minimum Part Size | 17 mm x 4 mm |
| Maximum Part Size | 300 mm x 650 mm |
| Minimum Wall Thickness | 0.8 mm |
| Maximum Wall Thickness | 12.7 mm |
| Quality Control | IS0 9001 Certified |
| Minimum Possible Batch | 1000 pcs |
Die Casting Parts Gallery
In order to help you understand our die casting capabilities, here are some of our previous products, and demo parts designed by engineers. Moldpartner is flexible for all types of die casting parts. So if you are looking for a die casting company for your projects, you need not look elsewhere!
