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How Die Casting Works

Die Casting: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.

CastingFamily
+/-0.1mmTypical tol.
5Route steps
175Parts in finder

Die casting forces molten metal, usually aluminium, zinc or magnesium, under high pressure into a hardened steel die. It produces thin-walled parts fast once the die is paid for.

At a glance

When to use it, and when not

Best for

High-volume non-ferrous parts with thin walls, fine detail and a good as-cast finish, such as housings and brackets.

Watch for

High tooling cost, gas porosity that limits heat treatment and welding, and a non-ferrous-only material range.

Step by step

The typical route

Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.

  1. Die prep

    Mount and heat the hardened steel die, spray release.
    Tooling Steel die   Tolerance -   Lead -

  2. Inject

    Shoot molten aluminium/zinc under high pressure, eject.
    Tooling HPDC   Tolerance -   Lead -

  3. Trim

    Trim the runner and overflow, deburr.
    Tooling Trim die   Tolerance -   Lead -

  4. Machine

    Face mating planes, bore seats, drill/tap ports.
    Tooling CNC   Tolerance -   Lead -

  5. Leak & inspect

    Pressure/leak test, then finish.
    Tooling -   Tolerance -   Lead -
Precision

Tolerances it can hold

TYPICAL TOLERANCE IT CAN HOLD
+/-0.1mm typicalcoarsefine+/-1mm+/-0.1mm+/-0.01mm+/-0.005mm
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials

Materials it suits

GradeWhy it suits this
Aluminium A380/ADC12Best castability, good strength
Zinc Zamak 3/5Low melt, fine detail, long die life
Magnesium AZ91Lightest structural
Design

Design tips

A few general pointers for Die Casting. The full, part-specific DFM list is in the dossier.

  • Thick/uneven walls. Thin and even them.
  • Bosses without draft. Add draft.
Cost

What it costs

Only pays above ~10k parts; below that, machine from billet or sand cast. The die is the whole economics.

PER-PART COST vs VOLUME
one-offat volumeVolume per order, low to highCost per part
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$400 to 900 per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER

Everything you need to quote and source it

The free route above is yours. To actually put a number on this process and buy it well:

  • Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
  • Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
  • A quote checker that tells you if a supplier quote is fair, and the red flags to watch
  • The full DFM list and a ready-to-send RFQ draft
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Examples

Parts made by Die Casting

175 parts in the finder use Die Casting as their primary process. A sample, each with its own guide:

action camerabadgebike partbracket metalbucklecamcarburetorcaseconnectorcoverdiediecastdji bodyemblemev frameev modulefittingfurnituregarlic pressgas burnergigacastgigacastinghandlehardwareheatsinkhobhot wheelshousingiron soleplatekettle baselevermatchboxminiaturemodelmonitor armmountnameplateoil panshoestep pulleyteslatooltoytoy carvalvezipper pullzipper slider
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FAQ

Frequently asked questions

How is a part made by Die Casting?
Die casting forces molten metal, usually aluminium, zinc or magnesium, under high pressure into a hardened steel die. It produces thin-walled parts fast once the die is paid for. The typical route is: Die prep; Inject; Trim; Machine; Leak & inspect. High-volume non-ferrous parts with thin walls, fine detail and a good as-cast finish, such as housings and brackets.
What does Die Casting cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $400 to 900 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Die Casting hold?
Typically about +/-0.1 mm, tighter with extra finishing operations at higher cost.
What materials suit Die Casting?
Common choices are Aluminium A380/ADC12 (Best castability, good strength); Zinc Zamak 3/5 (Low melt, fine detail, long die life); Magnesium AZ91 (Lightest structural).
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