Lists of high pressure die casting manufacturers and detailed information about the process
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High pressure die casting (HPDC) is a manufacturing technique where molten metal is forced into a mold or die at substantial pressure to create intricate implements, components, and parts. This method achieves high dimensional precision, tight tolerances, and an exceptionally smooth surface finish, often eliminating the necessity for secondary processing steps. Manufacturers often favor high pressure die casting over other techniques due to its speed, capacity for high volume output, and cost-effectiveness.
In high pressure die casting, pressure is generated through the use of hydraulics and pressurized gas, which propel a piston or ram to introduce the molten metal into the mold. The clamping mechanism ensures the mold is securely closed under high pressure while the metal solidifies. This rapid process transforms molten metal into near-net shapes within seconds.
Choosing high pressure die casting for manufacturing is often due to its capability to produce light, large alloy components in bulk quantities rapidly and efficiently. The components created not only boast excellent surface finishes and uniformity but also possess outstanding mechanical attributes. Although deburring might be required to eliminate flash around holes, parts generally do not need any additional processing. Moreover, complex and intricate geometries can be cast in a single unified piece.
The die casting process has been a cornerstone of precision metalworking and component manufacturing for over two centuries, enabling the efficient production of high-quality metal parts with complex shapes and tight tolerances. Initially, die casting involved pouring molten lead and tin into simple molds, primarily to produce type for California case printing presses. The true industrialization of die casting began in the early 20th century, introducing multi-cavity dies to manufacture a vast array of products for diverse industries. As advancements in technology and materials science drove innovation, the high pressure die casting (HPDC) process grew rapidly, incorporating a broader variety of non-ferrous metals such as aluminum, zinc, and magnesium alloys, and leading to the creation of more intricate, durable, and lightweight components for the automotive, aerospace, electronics, and consumer goods industries.
Although the HPDC process is adapted to each manufacturer’s specific applications and product requirements, the foundational steps remain integral across all use cases. High pressure die casting begins with a collaborative dialogue between the die casting company and the customer to define project goals, mechanical properties, and end-use parameters. Prior to initial consultations, customers often provide detailed 3D models or technical drawings for custom metal parts, which are carefully evaluated by HPDC engineers to ensure manufacturability, optimal wall thickness, and overall feasibility within the die casting workflow.
Leading high pressure die casting manufacturers maintain inventories of standard die molds for common parts, but new projects involving custom metal components generally require bespoke molds. The mold development process starts with advanced computer aided design (CAD) software or 3D computer rendering solutions to create precise dimensional specifications and seamless integration with the customer’s finished product. Engineering teams collaborate closely with clients to optimize mold design, ensuring appropriate draft angles, uniform wall thickness, and strategic placement of gates and vents to mitigate common casting defects such as porosity and misruns.
Meticulous attention to mold engineering is essential to minimize defects, maximize material efficiency, and reduce overall production costs. By simulating material flow and cooling patterns, designers address potential issues such as thermal stress, gas entrapment, and shrinkage in the earliest stages, enabling proactive solutions for reliable volume manufacturing. This thoroughness ultimately preserves resources, mitigates risk, and accelerates time to market for new cast products.
The high pressure die casting mold system is comprised of a cavity, core, inserts, sliders, and ejector pins. The two halves of the mold form the shape of the finished part, with robust steel plates and frames uniting them for precise installation in the die casting machine. This modular system supports rapid tooling changes and high-volume production runs, allowing manufacturers to serve a range of markets requiring both standard and custom die cast solutions.
A critical element of any high pressure die casting mold is the ejection system for removing solidified parts cleanly and efficiently. On the reverse side, the runner system—responsible for channeling high-pressure molten metal into the mold cavity—affects both filling speed and uniformity. The overflow and venting slots complete the system, venting gases and equalizing pressure during injection to ensure superior part quality and surface finish with minimal post-processing.
Types of high pressure die casting molds include prototype, rapid tooling, production, unit, and trim dies. Prototype molds use gravity casting or low-volume runs to validate designs before full-scale investment in machined steel dies. Rapid tooling supports quick turnaround prototyping for market testing, while hardened production dies—constructed from premium tool steels—enable the manufacture of thousands of parts over multiple cycles without significant wear or dimensional drift. Unit and trim dies facilitate specific secondary operations or high-precision edge trimming for superior part accuracy.
Before mounting the mold on the die casting machine, thorough surface preparation is required. The mold interior is treated with specialized die lubricants that function as mold release agents and thermal insulators. Maintaining proper temperature control by applying the correct lubricant formulation prevents soldering, material buildup, and premature tool wear—a crucial step for consistent mold longevity and high-quality finished castings. This thermal management step also facilitates easy ejection and preserves the surface finish of the high pressure die cast parts, especially for tight-tolerance or visually exposed components in sectors like automotive or consumer electronics.
Selection of the optimal material for high pressure die casting is dictated by component design, mechanical requirements, and cost considerations. Successful HPDC operations rely on a deep understanding of the properties and performance profiles offered by different non-ferrous alloys. Commonly utilized metals in the high pressure die casting process include:
Cold chamber high pressure die casting is required for metals and alloys with high melting points—such as aluminum, brass, and magnesium—whereas hot chamber high pressure die casting is ideal for low melting point materials like zinc, tin, lead, and select magnesium alloys. HPDC is especially valued in mass production due to its ability to rapidly create consistent, reliable, net-shape metal parts with minimal post-processing or machining requirements.
For consumers and industrial buyers, key considerations when selecting a metal for die casting include mechanical properties such as yield strength, ductility, and machinability; component application environment; corrosion resistance; and cost per unit volume. Materials engineers or procurement specialists often work with the die casting company to match alloy performance with production goals and total lifecycle costs.
There are two primary methods of injecting molten metal into the die cavity during high pressure die casting: the hot chamber and cold chamber processes. These processes are defined by the manner in which the metal is melted, the mechanism by which it is delivered into the mold, and the types of metals best suited to each method. Choosing the right injection method is a critical decision for both cost-effectiveness and achieving the desired mechanical properties in the finished die cast part.
Hot chamber high pressure die casting, sometimes referred to as direct injection die casting, is optimized for processing alloys with low melting temperatures, such as zinc, lead, tin, and select magnesium alloys. Utilizing a gooseneck mechanism integrated into the casting machine, a typical hot chamber HPDC system features an internal melting furnace, burner, cylinder, piston, nozzle, die, and hydraulic ejection pins.
During the hot chamber process, the alloy is melted in the internal furnace, allowing for continuous, automated production with minimal downtime. Once the molten metal reaches the desired temperature, it is drawn up into the gooseneck assembly and then forcibly injected under high pressure into the closed die cavity. This method ensures rapid cycle times and is highly efficient for high-volume production of small- to medium-sized parts with excellent surface finish and dimensional uniformity.
As the molten metal fills the die, hydraulic pressure is maintained until the casting solidifies—beginning at the mold walls and progressing inward. Proper management of injection pressure, die temperature, and fill speed are vital not only for eliminating porosity and incomplete filling but also for prolonging die life and ensuring the consistent quality of the high pressure die cast products.
Once solidification is sufficient, the dies are separated and the finished casting is ejected by mechanical pins. Ejection efficiency and cycle consistency are crucial for optimizing yield and reducing cycle costs in large-scale production environments.
Cold chamber high pressure die casting is the method of choice for alloys with high melting points, including aluminum, brass, and magnesium. In this variant, the melting of the metal occurs externally in a dedicated furnace. Once the desired melt quality and temperature are achieved, the metal is transferred via a ladle to the shot chamber of the die casting machine.
Within the cold chamber process, the shot chamber receives a metered quantity of molten metal (known as a “shot”), after which a hydraulic ram rapidly and forcefully injects the metal into the die cavity at extremely high pressures—ranging from 1,500 psi to over 25,000 psi. By maintaining such intense injection forces and high-speed fill rates, cold chamber HPDC prevents gas porosity, minimizes shrinkage, and produces dense, high-strength components with outstanding accuracy.
The cold chamber method is ideally suited for large, structural parts required in automotive, aerospace, and industrial equipment manufacturing, where aluminum die casting is a primary process for engine housings, transmission casings, and suspension components. This injection approach is also favored for medium to high production volumes demanding excellent mechanical properties and superior surface finishes, especially when casting larger or thicker-walled components.
After solidification, part ejection mirrors the hot chamber process; automated ejector pins remove the finished casting from the die cavity, paving the way for subsequent trimming and post-processing steps. The separation of melting and casting equipment in cold chamber HPDC boosts material versatility and supports continuous production with rapid setup changes for different alloys or product lines.
Trimming is an essential secondary operation in the high pressure die casting process, focused on removing excess material known as "flash," as well as runners and gates formed during injection. Flash accumulation—thin extrusions of metal along the parting line—results from the extreme pressures used during injection and the natural expansion of the molten alloy.
Proper trimming enhances dimensional accuracy, achieves final part geometry, and eliminates sharp edges or minor casting defects, yielding die castings that meet strict product specifications for appearance, function, and precision. For high-volume orders, automated trimming machines—often utilizing trim dies—provide fast and repeatable removal of gates, risers, and burrs in a single, integrated operation, improving production throughput and minimizing manual labor costs.
Effective trimming is crucial not only for the structural integrity of the finished HPDC part but also for optimizing downstream finishing processes such as deburring, shot blasting, painting, or plating. Careful handling during trimming ensures that the design intent and performance functionality of the part are preserved, while over-trimming is avoided to prevent any compromise to the casting's mechanical properties and long-term durability.
Manufacturers and engineers evaluating die casting services should prioritize partners with advanced trimming and finishing capabilities, as well as robust quality control protocols, to guarantee consistent, high-performance results—especially for complex or critical components destined for high-stakes applications in industries like automotive, medical devices, or industrial machinery.
There are several methods of die casting, which include gravity die casting, vacuum die casting, sand casting, and pressure die casting. The choice of die casting process is critical to the production of parts and components. Each of the methods has capabilities and restrictions that have to be considered when choosing casting to produce a component.
Casting manufacturers help guide clients through the casting manufacturing process to inform them as to the benefits and considerations it provides. In the case of high and low pressure die casting, there are stipulations that restrict certain types of metals, volume of production, and the properties of castings.
Cost is a major consideration for both high and low pressure die casting. It is important for casting customers to know the cost of the casting process, which is weighed against the high quality of the products that are produced. Low pressure die casting involves alloys with low melting points and the production of castings that weigh 150 kg. High pressure die casting uses soft alloys and performs at high speeds.
Tooling costs is an issue for all forms of die casting due the expense of forming and shaping dies and molds. The design of a mold, its complexity, and the types of materials are initial costs for both types of die casting. The pressure related to high pressure die casting necessitates the use of strong and more robust metals. The tooling has to endure rapid injection, which increases design costs. Low pressure die casting uses less pressure, a factor that decreases the wear on molds and dies.
Production volume is a major factor in differentiating the capabilities of high and low pressure die casting. HPDC is automated and used for high volume production runs, which amortizes the tooling costs and lowers per unit costs. When thousands of parts and components are needed, high pressure die casting is the best choice.
The slower cycle times of low pressure die casting makes it best for small runs of a few hundred parts. The lower tooling costs helps to keep the per unit cost down. LPDC can be an alternative but requires careful consideration since large quantities can be very costly.
As is indicated by volume, high pressure die casting has faster cycle times, which is the reason it can produce higher volumes of parts. The speed of injection makes it possible to have faster part production. Normal cycle times for HPDC for average parts is 200 to 300 shots per hour. For very small parts, such as zipper teeth, shots per cycle increase into the thousands. Shorter cycle times mean that more parts are produced per hour, a factor that increases productivity and lowers labor costs.
The length of the process for low pressure die casting is longer. The controlled molten metal filling process increases cycle times, which ends in lower throughput. In addition, the slow process increases labor and operational costs. Large orders take several hours and delay delivery times.
Die casting is a high energy consumption process. The amount of energy used by HPDC compared to LPDC is significant. High pressure die casting requires a great deal of energy to create the pressure for the faster cycle times. This increases operational costs and can have an impact on certain areas.
Although the slowness of low pressure die casting results in shorter product runs and long cycle times, it has a benefit in regard to energy costs. The lower pressure of LPDC lowers energy costs per cycle. The greater factor that influences energy costs for LPDC is the breadth and scale of production, which increase energy costs.
Both high pressure and low pressure die casting are capable of producing complex geometries with the basic difference being quantities and time. The key to their success is close attention to the process to ensure accuracy and adherence to design parameters. A cost that may be added to both processes is post processing and additional finishing steps due to flash, runners, and gates, factors that influence more complex components.
The factor that sets high pressure die casting apart from other casting methods is the speed and accuracy of casting production. Speed seems to be a dictating factor in modern manufacturing. High pressure die casting is widely used due to its speed and accuracy. While other casting methods may take hours to produce components, high pressure die casting can complete the process in minutes.
Aside from the speed of high pressure die casting, there are benefits in regard to the components that are shaped by the process. From carefully crafted dies to high quality finishes, high pressure die casting offers several benefits that have made it an essential aspect of part production.
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The high production rate is what is constantly pushed as a benefit of high pressure die casting. The speed of the process makes it possible to produce large quantities of parts in a short time, which lowers per unit costs. The number of cycles per hour varies in accordance with the parts being produced but can be as many as several hundred up to several thousands. This increase in units lowers the cost of each unit.
One of the disadvantages of LPDC is the limitation on how small the thickness of part walls can be. The pressure placed on the molten metal as it is injected into the die cavity forces the molten metal to every portion of the die, regardless of the thinness or thickness of the die. Wall thicknesses for high pressure die casting can be less than 2 mm for aluminum and as thin as 1 mm for zinc.
Having the ability to produce components with significantly thin walls makes it possible to manufacture lightweight components with sufficient strength and durability. In the modern age, this includes a wide range of industries such as aerospace, automotive, and electronics. Weight has become a major issue for the auto issue and has always been a concern for aerospace.
High tolerances are one of the major reasons for the popularity of die casting in general and high pressure die casting in particular. The dies for high pressure die casting are made from H13 tooled steel and precision machined to the micron level to produce castings with exceptional tolerances.
The tolerances for zinc castings are between ±0.001 in and ±0.002 in. For aluminum, casting tolerances can be between ±0.002 in and ±0.004 in. Tolerances for castings is important to ensure the casting meets the functional requirements of an application. The types of tolerances in high pressure die casting are linear, flatness, and parting lines, a factor that is examined to ensure part precision.
Porosity is a major concern in all forms of die casting. Trapped gases and air inside a casting create pores, which become weak points. Although HPDC creates turbulence when injecting molten metal, fast solidification and high pressure minimize potential porosity. When considering a method for producing a part or component, it is essential that the chosen method does not allow porosity.
The presence of openings, spaces, or pores in a casting ensures component failure and damage. The main feature of high pressure die casting is the pressure under which the molten metal is injected and continued until solidification. The constancy of the pressure as it presses up against the molten metal limits the potentiality of porosity.
The engineers and designers at high pressure die casting companies work diligently to ensure that none of their molds will produce pores. Although the pressure of the process severely limits the potential for the inclusion of pores, the design and tooling of the die ensures the prevention of porosity.
In any metal working process, grain structure is a major concern since it determines the strength and durability of a part or component. In high pressure die casting, pressure is applied to the molten metal until the casting solidifies. The process is quick and efficient. The speed of the high pressure die casting process allows the matrix of a casting to be consistent with small grains that improve the properties of the casting.
When a metal is processed, its microstructure is changed. Changes in the microstructure influence a metal’s properties. Strength, toughness, ductility, hardness, corrosion resistance, the effects of high or low temperatures, and resistance to wear are impacted. During the design phase of high pressure die casting, engineers carefully examine how the procedure will affect the microstructure of the final product and what its capabilities will be.
One of the factors related to changing the microstructure of a metal is its strength to weight ratio. A feature of high pressure die casting castings is their thin walls that have a fine microstructure. It is this aspect of the castings that separates the process from other forms of casting. The result of the fine microstructure is castings that are exceptionally strong, durable, lightweight, and tough.
The smooth even surface finish of HPDC castings is achieved by fast fill times and the smooth walls of the dies. Castings, in secondary processing, are blasted, painted, anodized, chrome plated, and polished to a mirror finish. The process for high pressure die casting delivers components with a superior finish, excellent uniformity, and outstanding mechanical properties. The dimensional accuracy and exceptional surface finish generally does not require machining, which further enhances the production process and lowers cost.
When customers choose high pressure die casting, they have a vision of the surface finish that their product requires. Working with HPDC engineers, they outline the nature and use of the product with a description of the necessary finish. The surface of a product is dictated by the mold, metal, and any forms of coatings. Consideration of the surface finish is a necessity when selecting high pressure die casting as a process.
For many years, die casting was restricted as to the size of castings. With the advent of bigger and better machines, high pressure die casting is used to produce engine blocks on 4500 ton and 6500 ton HPDC machines. As the size of machines has increased, the size of parts has matched the improvement with parts of thousands of millimeters and several feet being produced.
Intricate and complex designs of a wide range of sizes and weights are rapidly being produced. The addition of the production process of HPDC is changing the face of modern industry. With the restriction on the process eliminated, HPDC can be used to produce any form of product at extremely high quality in line with manufacturing standards.
Many products require heat treatment to harden them and make them more durable. This aspect of production has not always been available for HPDC products until recently. The increasing use of HPDC as a production method has necessitated finding a method to heat the parts being produced. High volume production and exceptional grain structures have made high pressure die casting the first choice for part production. A caveat related to choosing the process was the inability of heat treating HPDC parts.
After dedicated research, engineers developed a method that is used to heat treat HPDC parts and make them usable for products requiring increased hardness. This revelation has further expanded the dependence on HPDC as a production method. In addition, conventional heat treating methods are used that include cooling a part and then reheating it in an oven.
Choosing the right metal for a high pressure die casting project is a critical aspect of the manufacturing process. Metal selection is included in the early phases of the design process since the type and properties of a metal determine how it can be included in an application. The choice of a metal is determined by a metal’s durability, strength, and overall quality.
High pressure die casting components are made of aluminum, magnesium, and zinc, which are chosen for their resistance to corrosion, high strength, and non-magnetic properties. Of the three metals, aluminum has become the most widely used due to its resistance to corrosion and rust.
The choice of a die casting metal is determined by the parameters of a project’s requirements and the application for which a product is being produced. The three factors customers use when selecting a metal are:
Magnesium is lighter than aluminum and easier to cast due to its fit with the process. Alloys of magnesium that are typically used in high pressure die cast are:
AZ91D – AZ91D has a high strength-to-weight ratio, corrosion resistance, and castability.
AM60 – AM60 includes strength, ductility, vibration dampening, and castability and is the first choice for casting auto parts.
AS41B and AE42 – AS41B and AE42 rare earth alloys with high-temperature, creep, corrosion, and ductility resistance but are very expensive alloys.
The benefits of magnesium include:
There are several factors that differentiate zinc from magnesium and aluminum. Its smooth surface finish provides high aesthetic appeal with tight tolerances. Zinc can be used to cast any type of product of any size. The alloys of zinc used for HPDC casting include:
Zamak 3 – Zamak 3 is known for its dimensional stability and ease of casting.
Zamak 2 – Zamak 2 is an expensive zinc alloy with great strength.
Zamak 5 – Zamak 5 is less ductile but has higher tensile strength.
The many benefits of zinc include:
Since its discovery in the 19th century, aluminum has become the most commonly used metal for a wide range of products and applications. Lightweight, corrosion resistant, and electrically conductive, aluminum is normally the first choice for the manufacture of castings. Certain grades of aluminum have strength and durability that is comparable to grades of steel. Aluminum alloys that are typically used for high pressure casting are:
A360 – A360 is used in die casting because of its excellent strength and heat resistance. It is a good choice for parts that require toughness and durability, such as automotive components and aircraft parts.
A380 – A380 is known for its fluidity, which makes it easy to cast complex shapes with thin walls. Its mechanical properties include high strength, corrosion resistance, and thermal conductivity.
A383 – A383 is a version of A380 with exceptional strength and good conductivity.
A413 – A413 is a good choice for applications that require excellent corrosion resistance and high strength.
A319 – A319 is commonly used for automotive and industrial applications.
A356 – A356 is widely used in high pressure casting due to its castability and strength.
There is a long list of benefits that manufacturers can provide regarding the use of aluminum. A short list of those benefits include:
The high quality of products produced by high pressure die casting has made it a production partner with a diverse set of industries. The speed at which components are produced and the quantities make HPDC ideal for the manufacturing of any size part or component. High pressure die casting has been around for many years and has been used to produce tight tolerance parts. In recent years, the diversity of the ways that HPDC can be used has been ever expanding as new and innovative methods of including it in the production of various applications are being discovered.
The auto industry purchases more castings than any other industry. Engine blocks, gearbox casings, oil sumps, engine mountings, and structural parts are manufactured using HPDC. The strength and durability of components produced using HPDC are unmatched by any other manufacturing method.
The emphasis that has been placed on auto manufacturers to lighten the weight of cars has required manufacturers to find ways to decrease car weight. High pressure die casting offers a solution by producing strong durable components that match weight requirements.
Central paradigms for the construction industry are strength, durability, and longevity. Unlike other industries where products have a time limit, buildings, materials, and structures are expected to last for many years. It is for these reasons that the construction industry uses components, parts, and other features produced by high pressure die casting. Window frames, roof superstructures, total building frames, bridges, and skyscrapers are constructed using HPDC castings. Components are lightweight, sturdy, strong, durable, and, above all, long lasting.
Referred to as structural components and structural die casting in the high pressure die casting industry, components produced for the construction have to meet the requirements of being lightweight and strong. In addition, they have to be dimensionally accurate with tight tolerances to fit into a structure's architectural design.
The aerospace industry has strict standards regarding the components used to construct aircraft. Many of the regulations are for safety reasons and the protection of occupants. HPDC is popular with the aerospace industry due to the process’ ability to produce intricate and complex designs. The planning and construction of aircraft is a carefully controlled and monitored process that examines, in detail, every step. The lightweight and superior quality of HPDC parts makes it the ideal process for aerospace manufacturing. Aside from the durability and strength of parts, the repeatability, consistency, and precision of the process is a perfect match.
Medical devices have strict stipulations regarding accuracy and precision. The proper assembly of such devices ensures high quality performance, safety, and adaptability. Ultrasound systems, pacemakers, dialysis equipment, and medical robots require intricate components that are produced by high pressure die casting. Manufactured components are designed to meet the high standards of medical professionals. The tools are lightweight and easy to handle in hospital rooms and surgical theaters.
In the renewable energy industry, high pressure die cast is used to manufacture piping, drilling equipment, valves, impellers, and brackets for solar panels. As with the construction industry, components for the energy sector have to be strong, durable, and long lasting to meet the requirements of sustainability.
There is a very long list of components that are produced for the electronics industry using high pressure die casting. From connectors and housings to heat sinks and handles and knobs, the HPDC supplies high quality products, parts, components, and tools. The choice of HPDC as a producer is due to the mechanical properties of components, their low cost, and their precision and complexity. In the majority of cases, zinc is the metal used to manufacture tools for the electronics industry.
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