Aluminum Die Casting Services

Lightweight, high-strength aluminum die casting in A380, A356, A413, and ADC12 alloys. Cold-chamber machines from 160 to 1,650 tons produce thin-wall, pressure-tight castings for automotive, electronics, and industrial applications — with in-house tooling and CNC finishing under one roof.

Free Consultation
3-8 Weeks
Tooling Lead Time
±0.05mm
Casting Tolerance
1.0mm
Min Wall Thickness
500 - 1,000,000 pcs
Batch Flexibility

Materials

Grade Properties Typical Applications
A380 (EN AC-46500 equiv.) Tensile Strength: 320 MPa, Density: 2.71 g/cm³, excellent castability and pressure tightness, best all-around die casting alloy Housings, brackets, gearbox cases, power tool bodies, general industrial components
A356 (heat treatable) Tensile Strength: 310 MPa (T6), Density: 2.68 g/cm³, heat treatable for higher strength, excellent elongation and impact resistance Structural automotive parts, wheels, suspension components, aerospace brackets
A413 (thin-wall specialist) Tensile Strength: 295 MPa, Density: 2.66 g/cm³, outstanding fluidity for thin walls, excellent pressure tightness Electronics enclosures, telecom housings, hydraulic components, waterproof casings
ADC12 (JIS standard) Tensile Strength: 310 MPa, Density: 2.68 g/cm³, most common Asian die casting alloy, excellent machinability and castability Automotive components, motor housings, heat sinks, consumer product frames
A360 Tensile Strength: 320 MPa, Density: 2.63 g/cm³, superior corrosion resistance and pressure tightness vs A380 Marine hardware, outdoor equipment, pneumatic components
Zinc & Magnesium (also available) Zamak 3/5/27 for high-detail thin parts; AZ91D magnesium for ultra-lightweight applications See our zinc die casting service page; magnesium available on request for weight-critical programs

Process Parameters

Parameter Standard Range
Process Cold-chamber high-pressure die casting
Machine Range 160 - 1,650 tons clamping force
Casting Temperature 650 - 720°C
Injection Pressure 300 - 1,500 bar
Max Casting Size 600mm x 500mm x 200mm
Casting Weight Range 10g - 8kg
Dimensional Tolerance (As-cast) ±0.05mm - ±0.1mm (per NADCA standards)
Dimensional Tolerance (Post-CNC) ±0.02mm on machined features
Min Wall Thickness 1.0 - 1.5mm (alloy and geometry dependent)
Draft Angle 1-3° cores, 0.5-1° cavities
Cycle Time 30 - 90 seconds (part dependent)

Surface Finishes

As-Cast

Natural die-cast surface direct from the tool, Ra 1.6μm - 3.2μm achievable with polished die surfaces. Most economical option, suitable for internal components and painted parts.

Shot Blasting

Uniform matte texture that removes flash witness and evens out surface appearance. Standard preparation step before powder coating or painting. Steel shot or stainless media available.

CNC Machining

In-house CNC milling and turning of critical features: sealing faces, bearing bores, threaded holes, and datum surfaces machined to ±0.02mm. Combined casting + machining under one quality plan.

Powder Coating / Painting

Electrostatic powder coating with custom RAL color matching, 60-120μm thickness for outdoor durability. Wet painting for complex color requirements. Pre-treatment includes degreasing and chromating.

Anodizing (A356/A413)

Decorative and protective anodizing for low-silicon alloys. Note: high-silicon alloys like A380/ADC12 anodize dark gray — we advise on alloy selection when cosmetic anodizing is required.

Chromate Conversion (Alodine)

Chemical conversion coating providing corrosion protection and excellent paint adhesion base, with minimal dimensional impact. RoHS-compliant trivalent chemistry available.

Electroplating (Nickel/Chrome)

Copper-nickel-chrome plating systems for decorative and functional requirements. Pre-polishing of casting surface included for cosmetic-grade results.

Design for Manufacturing (DFM)

Tooling & Capacity

Type Lead Time Suitable For
Prototype Die (Single Cavity) 2-3 weeks 500 - 5,000 pcs, design validation, pre-production runs, market testing
Production Die (H13 Steel) 3-8 weeks 5,000 - 1,000,000+ pcs, hardened and nitrided for 100,000+ shot life
Multi-Cavity Die (2-8 cavities) 4-8 weeks High-volume programs, lower per-part cost, balanced runner systems
Trim Die & Fixtures 1-2 weeks (with main die) Clean gate removal, consistent flash trimming, production efficiency

Quality Assurance

Applications

Why Choose FHY Precision

✓ Integrated factory: die design, die making, casting, CNC machining, and finishing under one roof in Jieyang, Guangdong
✓ Cold-chamber machines from 160 to 1,650 tons cover castings from 10g to 8kg
✓ Thin-wall capability to 1.0mm with A413 for lightweight electronics enclosures
✓ In-house CNC machining delivers ±0.02mm on critical features — casting and machining under one quality plan
✓ MOQ 500 pieces with prototype dies from 2-3 weeks for low-risk market validation
✓ X-ray, leak testing, and spectrometer verification for pressure-tight and structural castings
✓ ISO 9001:2015 certified; IATF 16949 protocols available for automotive programs
✓ Free DFM report within 24 hours: wall thickness, draft, gating, and porosity risk analysis included

FAQ

1. What is the minimum order quantity (MOQ) for aluminum die casting?
Our die casting MOQ is 500 pieces, suitable for prototype and low-volume production. With a prototype die (2-3 weeks, significantly cheaper than production tooling), you can validate your design and market with 500-5,000 pieces before investing in hardened production tooling. CNC machined prototypes are also available before any tooling investment — MOQ 1 piece.
2. Which aluminum alloy should I choose for my part?
A380 is the best all-around choice: excellent castability, good strength, and pressure tightness — ideal for housings and brackets. A356 is heat treatable for structural parts needing higher elongation. A413 has outstanding fluidity for thin walls (down to 1.0mm) and waterproof enclosures. ADC12 is the JIS-standard equivalent common in Asian automotive supply chains. Share your requirements and our engineers will recommend the optimal alloy in the free DFM report.
3. How long does die casting tooling take?
Prototype dies: 2-3 weeks. Production dies (H13 steel, hardened and nitrided): 3-8 weeks depending on complexity and cavity count. Multi-cavity dies: 4-8 weeks. Trim dies and fixtures are built in parallel with the main die. Every tooling quote includes a confirmed T1 sample date, and first articles are CMM-verified before production release.
4. What tolerances can you achieve with aluminum die casting?
As-cast tolerances: ±0.05mm - ±0.1mm per NADCA standards depending on dimension size and location relative to parting line. For tighter requirements, our in-house CNC machining holds ±0.02mm on critical features like sealing faces, bearing bores, and datum surfaces. Combining casting with targeted machining is the most economical path to precision.
5. How do you control porosity in die castings?
Porosity control starts in DFM: uniform wall design, correct gate and overflow placement, and venting analysis. In production we monitor injection pressure, die temperature, and shot weight with alarm limits. For pressure-tight or structural parts, we offer X-ray inspection and leak testing to customer-specified rates. Vacuum-assisted casting is available for demanding applications.
6. Do you provide free DFM analysis before tooling?
Yes. Upload your STEP/IGES file and we return a free DFM report within 24 hours covering wall thickness distribution, draft angles, gate location, porosity risk zones, parting line placement, and manufacturability risks. Fixing these issues on screen costs nothing; fixing them in hardened steel is expensive. This review is standard before every tooling quote.
7. What CAD file formats do you accept?
We accept STEP (.stp/.step), IGES (.igs), Parasolid (.x_t), SolidWorks (.sldprt), STL, DXF, DWG, and PDF drawings. For die casting, 3D STEP models are preferred as the master definition. If you only have 2D drawings or physical samples, we offer reverse engineering to create production-ready 3D models.
8. What surface finishes are available for die cast parts?
As-cast, shot blasting, CNC machining of critical features, powder coating (custom RAL colors), wet painting, chromate conversion (RoHS-compliant), electroplating (nickel/chrome), and anodizing. Note: high-silicon alloys (A380/ADC12) anodize dark gray, so for cosmetic anodizing we recommend A356 or A413 — we advise on alloy-finish compatibility during DFM.
9. How is pricing calculated for die cast parts?
Part price = Alloy cost + Casting cycle cost + Trimming + Machining + Surface finishing + Inspection. Tooling price = Die complexity × Cavity count × Steel grade. Per-part cost drops significantly with volume as tooling amortizes. We provide detailed quotations within 24 hours, including separate tooling and per-part pricing so you can model total program cost.
10. Can you provide samples before mass production?
Yes. We supply T1 first-article samples from the die for your approval, CMM-verified with a full dimensional report. Design iterations at the prototype die stage are fast and economical. We can also CNC machine prototypes from solid aluminum before any tooling investment — ideal for fit and function testing while the die is being built.
11. Do you have ISO certification?
FHY Precision is ISO 9001:2015 certified. We maintain full material traceability with spectrometer verification and melt certificates for every alloy batch. IATF 16949 protocols can be arranged for automotive programs, including PPAP documentation, capability studies, and control plans.
12. How do you ensure consistent quality across production runs?
Process parameters (injection pressure, die temperature, shot weight) are monitored with alarm limits every shot. Die maintenance follows a shot-count program to prevent quality drift over tool life. CMM sampling at defined intervals, X-ray and leak testing where specified, and a full dimensional and cosmetic report ships with every order. Statistical data is shared on request.
13. Do you sign NDA before reviewing design files?
Yes, we sign NDA before quotation, not just before production. Your CAD files, product specifications, and program information are treated as confidential assets. We serve clients in automotive, electronics, and industrial sectors where IP protection is critical — NDA signing is our standard practice.
14. Do you ship internationally? How is export packaging handled?
We ship worldwide via DHL, FedEx, and sea freight. Export packaging follows international standards: anti-rust treatment, foam or blister trays for cosmetic parts, and IPPC-certified wooden crates for sea freight. Every shipment includes packing list, Certificate of Origin, and commercial invoice. Sea freight to US/Europe typically takes 3-5 weeks.
15. Can you handle casting, machining, finishing, and assembly together?
Yes. Our integrated factory handles die design and making, casting, trimming, CNC machining, surface finishing, and light assembly under one purchase order with a single quality plan. This one-stop approach reduces supplier management overhead, eliminates dimensional disputes between vendors, and shortens your total lead time.
16. What is the difference between die casting and other aluminum processes?
High-pressure die casting excels at high volumes (500+ pieces) with thin walls, fine detail, and excellent surface finish — tooling investment is repaid by low per-part cost. Sand casting suits very large parts and small quantities but with rougher surfaces and looser tolerances. Gravity/permanent mold casting sits between them. CNC machining from billet is best for quantities under 500 or when tooling lead time is unacceptable. We offer both die casting and CNC machining, and will recommend the most economical process for your volume in the DFM report.

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Ready to Start Your Aluminum Die Casting Project?

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