Die casting

Overview

Die casting injects non-ferrous molten metal into hardened steel dies under high pressure. It yields net-shape features with thin walls and excellent repeatability—common for connectors, housings, heatsinks, and mechanical brackets where CNC stock removal would waste material.

When to choose

• Moderate to high volumes where cavity count and cycle economics beat machining bars.
• Thin walls, ribs, and bosses integrated into one casting instead of welded assemblies.
• Zinc alloys for precision mechanical interfaces; aluminum alloys for structural or thermal mass.
• Cosmetic metal enclosures where flash removal and finishing plans are defined.

Process risks

• Porosity near thick sections or sudden wall transitions—needs venting and simulation discipline.
• Draft and radii requirements exceed plastics in many zinc layouts.
• Heat treat and aging responses vary by alloy—confirm mechanical targets with supplier data.

Secondary operations

Critical sealing surfaces, bearing bores, or datum features often receive light machining after casting. Include machining allowances and datum schemes on drawings.