Die casting forces molten metal under high pressure into a steel mold (die). Aluminum die casting produces parts with excellent dimensional accuracy, smooth surfaces, and high production rates.
Molten aluminum (usually A380, ADC12, or A356) is injected at 10-200 MPa into a hardened steel die. The metal solidifies rapidly (0.1-0.5 seconds), then the die opens and ejector pins push the part out. Cycle times range from 30 seconds to 5 minutes depending on part size.
Hot chamber — the injection mechanism is submerged in molten metal. Fast cycles, suitable for zinc and magnesium. Not used for aluminum (attacks the steel components). Cold chamber — molten metal is ladled into a shot sleeve, then injected. Required for aluminum and copper alloys.
Automotive (engine blocks, transmission cases, structural components), electronics (laptop frames, heatsinks), power tools (housings, gear cases), aerospace brackets, and lighting fixtures.
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