"Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from non-ferrous metals." (source: Wikipedia). It's known as "pressure die casting" in Europe.

"Gravity casting" (a.k.a. "permanent mold casting" in USA and Canada) uses gravity to fill the mold.

Here are some basic design guidelines for die casting parts:

1. Even wall thickness.
2. Roudning of all edges and corners.
3. Smooth blending and continuity of all the features.

We will provide additional design modifcation suggestions to make sure your parts are casted successfully.

Yes, we can put PEM studs, nuts, Southco fasteners, or hardware like McMaster-Carr components or inserts to the casted parts.

You can start by providing the part's 2D and 3D drawings to us. We can provide Design For Manufacture (DFM) service for you—plese see our Design for Manufacture Tips for Die Cast Parts article.

Please provide us with the part's 3D CAD drawings (such as IGES, STEP, or X_T). We can also quote based on 2D drawings (in DWG, DXF, or even PDF format [but with weight information]). We can also import CAD files directly from popular CAD software, such as Pro/ENGINEER, UGS, Catia, and Solid Edge. In addition, we need the production information listed in our request for quote form. Quoting turnaorund is typically within a week, and can be even sooner if there is special timing constraint.

Magnesium has a density of 1.74 g/cm³, and is the lightest structural metal in common use. Aluminium has a density of about 2.71 g/cm³, and is the most widely used alloy for castings worldwide. Zinc offers a wide range of excellent physical and mechanical properties, and can be used to achieve thinner sections in the parts. Please see the page on material properties .

You can specify your color by using RAL or Pantone color codes. If you don’t have the color code, you can send us a color chip or a color sample for us to come up with a matching color chip.

Due to our specialty in short run orders, we are very flexible in order quantities. Our quotes always break down pricing by MOQ's: e.g., there might be a price premium if orders are below 3,000 pcs., and another one if orders are below 1,500 pcs. (these numbers vary and are just for examples).

Magnesium is: among 1) the lightest of all metals (63% of aluminum, 38% of titanium); 2) stronger than engineering plastics; 3) 100 times better in heat dissipation than plastics; 4) electromagnetic-shielding; 5) best in vibration absorption of all metals; 6) environmentally safe (non-hazardous and recyclable); 7) easy to machine; 8) abundant in supply (sixth most abundant on earth).

We support NADCA standard tolerance for die castings.

Die casting process produces smoother surface than other casting processes:

• the surface roughness value of die cast part is 0.5 Ra, whereas
• the surface roughness value of machined parts is 0.43 Ra.

Note that the general buffing sander has a roughness value of 1.6 Ra, therefore general sanding does not provide smoother surface than die casting itself already produces.

Magnesium alloys are the lightest of the three: magnesium alloy will be 2/3 the weight of aluminum alloy, and 1/4 the weight of iron.

The following methods can improve the shrinkage issue on the front side:

1. Face milling
2. Rough polishing
3. Sandblasting or vibration polishing
4. Sandblasting with paint

Yes, aluminum and magnesium alloy die-casting can share the same mold, but, no, aluminum and zinc alloy die-casting cannot share the same mold.

Aluminum (ADC12) density: 2.70 g/cm3; Magnesium (AZ91D) density: 1.74 g/cm3; Zinc (Zamak #3) density: 6.7 g/cm3

Rib height: 4mm, width: 2.5mm. Draft angle: 5° on one side, with a root chamfer of R1 to R2.

Height of the heat dissipation fins: 15mm, width at the small end: 2.5mm. Draft angle: 3°, with a root chamfer of R1 to R3.

The small end of the rib is 3mm with a draft angle of 1.5°, the large end is approximately 7mm or more, and the thickness design is 4 to 5mm for optimal average thickness.

In general, die-cast parts contain silicon, and after anodizing, they will appear in an uneven grayish black color. If anodizing is required, we recommend to use A356 alloy and sandblast before anodizing to achieve a more uniform surface. For surface treatment of die-cast parts in general, we recommend to primarily use powder coating ("baked paint"). Die-cast parts can be transparent-anodized, and will retain their original color afterwards.

No, magnesium die-casting cannot be anodized.

Corner designs with small molds are prone to cracking, so we recommend to add a fillet radius (R). For irregular weight reduction, one can fill in the surrounding shapes, modify the spacing, and connect with ribs.

For die-cast parts with a thickness of less than 1.5 mm, ribs can be added on non-visible surfaces of the product to help support and prevent deformation. These ribs can be retained or removed through post-processing (milling).

The minimum thickness for aluminum alloy die cast parts is 1.5 mm; for magnesium alloy die cast parts, the best production thickness is between 1.0 to 2.0 mm; and for zinc alloy die cast parts, the minimum thickness is 1.2 mm.

Depending on the tolerance requirements, precision waterproofing is recommended to undergo CNC post-processing. For general purpose dust-proofing, it can be die cast directly.

Aluminum and magnesium alloy die-casting molds are guaranteed for 80,000 cycles; zinc alloy molds are guaranteed for 200,000 cycles; plastic injection molds are about 300,000 to 500,000 cycles. Stamping molds are approximately 100,000 cycles (the samping molds themselves do not break; it's the stamping pins that wear out or break, and they can be removed for grinding repair or replaced).

The available shipping methods are: Land Freight, Mail, Express delivery, Sea freight, and Air freight.

Depending on the budget, common packaging options are: plastic bag, bubble wrap, non-woven fabric, bubble cloth, foam, polyethylene, honeycomb paper, packing peanuts (foam chips), EPE (expanded polyethylene foam), and custom cardboard/inner/honeycomb/wooden box.

CNC machining is needed when flatness requirement is less than 0.25mm.

The available surface treatment process for die casting are:

• Grinding
• Deburring
• Sandblasting
• Vibrating (or Vibration finishing)
• Cleaning
• Ultrasonic
• Liquid baking paint
• Powder baking paint
• Anodizing
• Hard anodizing
• Electrophoretic deposition
• Electroplating
• Brushing
• Passivation and electro-polishing
• Micro-arc oxidation
• Coating
• Non-chromate treatment
• Printing

Yes, we routinely sign mutually-agreed-upon NDAs with prospective customers since 1998!

Typically multi-cavity tooling can be appropriate for parts that are relatively small and simple in shape, and will be produced in large quantities.

Yes, magnesium alloy be used to make fully machined CNC prototypes.

We recommend to reduce the threading depth by 0.5 to 1 mm to avoid protrusions from machining holes on the back side. If the threading depth cannot be reduced due to product requirements, it will be necessary to use a flat-bottom milling cutter to process the hole and then use a thread milling cutter to cut the threads, adding to the cost of production.

The edges should be chamfered by 0.2 to 0.5 C to avoid sharp edges.

We can design the mold to modify the 3D undercuts. Alternatively, we can use a T-shaped cutter for post-processing machining.

A sloped design at one direction of the column should be at 2/3 of its height for easy casting material entry and filling. The other three directions need ribs for support, with the rib height at about 1/2 of the column height. If the column requires threaded holes, micro-forming techniques should be used to prevent sand hole formations.

One common miss in design drawings is not specifying key dimensions or tolerances for the assembly areas prior to the tooling being made. These key dimensions or tolerances are added only after customers assemble with the first samples, resulting in issues during subsequent volume production.

During volume production, we can overcome the above miss by (in order of priority/preference, and in collaboration with the customers):

• relaxing tolerances where possible to align with actual production needs, or
• modifying the mold (without adding inserts), or
• adding inserts if absolutely needed, which will shorten the mold's lifespan.

We need to increase the draft angle or directly modify the 3D material drawing for approval.

We'd either request the customer to revise design, or to amend in post processing via machining or grinding.

If the draft angle is 0 degrees, machining is required; a draft angle of 0.5 to 2 degrees is more common.

The design should consider ease of replacement as much as possible, focusing on quick-disassembly features. The economical horn-type ejector is the most common, but options for hydraulic cylinder-type or horn and hydraulic plus linkage mechanisms for ejection are also available.

In general, for forming holes with diameters below Ø2.5mm or between Ø2.5mm and above 5mm, it is recommended to process with machining solids.

The tolerances for investment casting are inherently slightly larger than those for die casting, and with a greater shrinkage rate. If there are tolerance requirements for hole spacing, it is recommended to modify with machining.

The baking temperature for coating is 60 to 80 degrees C.

Use an air gun to blow over before baking. Additionally, individually blow through the threaded holes with an air gun to avoid these issues.