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 Consultation3-8 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)
- Keep wall thickness uniform between 1.5-4.0mm — abrupt thickness changes cause porosity and sink marks
- Apply 1-3° draft on cores and 0.5-1° on cavities for clean ejection without drag marks
- Use generous fillet radii (min 0.5mm, prefer 1-2mm) to improve metal flow and reduce stress concentration
- Add ribs instead of thick sections for stiffness — solid bosses over 6mm thick will have internal porosity
- Plan 0.3-0.5mm CNC machining allowance on sealing faces, bearing bores, and critical datums
- Design boss inner diameters with cast-in pilot holes to reduce machining and improve concentricity
- Avoid undercuts requiring slides where possible — each slide adds tooling cost and maintenance
- Locate parting lines and ejector pins on non-cosmetic surfaces; tell us which faces are Class A
- Specify pressure-tightness requirements (bar, leak rate) upfront so we design gating and overflow accordingly
- Upload STEP/IGES files for a free DFM report within 24 hours covering wall thickness, draft, gate location, and porosity risk zones
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
- Incoming alloy verification by spectrometer with melt certificate for every batch
- In-process monitoring of injection pressure, die temperature, and shot weight with alarm limits
- X-ray inspection available for internal porosity verification on pressure-tight and structural parts
- CMM inspection on first article and periodic samples with full dimensional reports
- Leak testing (air decay or submersion) for pressure-tight castings to customer-specified rates
- Mechanical property verification: hardness testing and tensile bars cast per lot on request
- Visual inspection standards agreed per surface class (Class A/B/C) before production
- Full dimensional and cosmetic shipment report with every order
- Die maintenance program with shot-count tracking to ensure consistent quality over tool life
- Quality system documented and controlled; third-party inspection (SGS, Bureau Veritas, T\u00dcV) available for automotive programs
Applications
- Automotive: brackets, housings, heat sinks, EV battery enclosures, motor end caps, steering components
- Electronics: heat sinks, telecom enclosures, LED lighting housings, RF shielding frames
- Power tools: gearbox housings, motor bodies, guard components, handle frames
- Industrial: pump bodies, valve housings, pneumatic manifolds, compressor components
- Lighting: LED heat sink housings, street light bodies, floodlight enclosures with thermal fins
- Appliances: coffee machine frames, kitchen equipment housings, HVAC components
- Drones & robotics: motor mounts, frame components, gimbal housings requiring light weight
- Furniture & architecture: structural connectors, decorative hardware, handle systems
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
quality system documented and controlled; capability studies, and control plans 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 offer third-party inspection (SGS / Bureau Veritas)?
Yes. On request we can arrange independent third-party inspection by SGS or Bureau Veritas at any stage - before shipment, during production, or on incoming material. You receive a full independent inspection report (dimensional CMM measurement, material verification, and appearance/surface check) so parts are verified by a neutral party before leaving our facility.
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.