Die casting is a metal‑casting process commonly employed by die‑casting manufacturers, characterized by the application of high pressure to molten metal within the cavity of a mold. The molds are typically made from high‑strength alloys. This process bears some resemblance to injection molding. Most die‑cast parts are made from non‑ferrous metals, such as zinc, copper, aluminum, magnesium, lead, tin, and lead‑tin alloys and their derivatives. Depending on the type of die casting, manufacturers must use either a cold‑chamber or a hot‑chamber die‑casting machine.

The casting equipment and molds used in die casting are relatively expensive, which is why this process is typically employed only for mass production of large volumes. Manufacturing die-cast parts is comparatively straightforward, usually requiring just four main steps, and the incremental cost per part remains very low. Die casting is particularly well suited to producing high‑volume small and medium‑sized castings, making it one of the most widely used casting methods. Compared with other casting techniques, die casting yields smoother surfaces and greater dimensional consistency.

Building on traditional die‑casting processes, manufacturers have developed several advanced techniques, including porosity‑free die casting, which reduces casting defects and eliminates porosity. Primarily used for zinc alloys, this method minimizes scrap and boosts throughput in direct‑injection operations. Additionally, new die‑casting technologies have emerged, such as precision die casting and semi‑solid die casting.

The traditional die‑casting process employed by die‑casting manufacturers comprises four primary steps: high‑pressure die casting. These steps—mold preparation, filling, injection, and shaking—form the foundation for various advanced die‑casting techniques. During mold preparation, a lubricant is sprayed into the mold cavity; in addition to helping regulate mold temperature, the lubricant also facilitates demolding of the cast part. Next, the die‑casting operator closes the mold and injects molten metal under high pressure. After the cavity is filled, pressure is maintained until the casting solidifies. Finally, an ejector pin removes the finished part from the mold. Because a single mold may contain multiple cavities, die‑casting manufacturers can produce several parts in each cycle.

Low-pressure castings feature a dense microstructure, excellent gas tightness, stable dimensional accuracy, and reduced machining requirements, making them well suited for a wide range of sealed, pressure‑bearing components. We offer custom mold development based on your drawings or samples, and can tailor the casting process to meet specific operating conditions. Non‑standard, irregular‑shaped parts and castings in special specifications are also available upon request.