Aerospace and Defense

Industrial

Medical and Dental

Consumer electronics 

What is Die Casting?

 

Metal die casting is a production process used to make geometrically-complex parts with attractive finishes through custom-made steel mold. The process is quite similar to injection molding, where molten metal is forced into the die to create casted parts. The cast parts take the shape of the die and solidify as the die/mold cavity cools. On cooling, the final piece is removed and post-processed to bring it to the desired finish. Die casting is the most effective approach to making medium to high units of metal parts for end-use. 

 

Die casting allow for the creation of high-quality metal parts with high accuracy and ensures that the process is highly repeatable. The die casting process is carried out with the use of a furnace, the metal material, the die casting equipment and the die itself. Aluminum, zinc and magnesium are the most common die casting alloys.

At First Part China Limited, our die casting process is meticulously outlined to produce intricate shapes that are geometrically complex without compromising on the quality, turn around, repeatability and durability. Our Pressure Die Casting service is one of the most cost-effective and methods for producing high-fidelity low to medium volume manufacturing of your metal parts with tight tolerances, excellent surface finishes and dimensional precision. Our experience of over ten years has allowed us to leverage our machine capabilities to deliver low-volume batch production of as little as 50 to 1000 units, while operations are very scalable to achieve up to 1,000,000 parts at an even lower cost-per-part.

Advantages Of Die Casting

 

· High-quality Parts

Parts created through die casting are stronger, more rigid, and have a longer life span than those made through other techniques.

Robotics

Automotive

Energy

Education

Electronics

Quality and Reliability

First Part is dedicated to meeting high quality standards, delivering part on time with precision, accuracy and reliability. We follow strict quality control systems to ensure that only the best parts are delivered.

Finishing Options

 

Die casted parts naturally have an excellent surface texture. Depending on the end-use, however, these castings can be further finished in many ways that may represent pure cosmetic cases or offer some form of protection to the part. Finishes should beautify, enhance the sophistication and functionality of any part. At First Part, our cast parts may be finished in any of the following options: 

· Sandblasting

A finishing operation that involves the use of sand particles as an abrasive media to smoothen a part. Here, fine sand particles are directed at a part’s surface under high pressure. Sandblasting creates a smooth, uniform surface finish on the part.

· Tight Tolerances and Dimensional Accuracy

The high pressure involved in die casting makes it capable of capturing critical details and achieving tight tolerances. Die casting can also produce parts with thin walls and high dimensional accuracy for instances where a part is crucial to performance and functionality.

· Excellent Surface Finish

Die casting can capture even the most intricate details of any design in a mold and use pressure to transfer these details to the part. The surface finish of castings is near perfect post-production but may be further improved through custom finish options.

· Mass Production

Die casting is the most cost-effective method for making large volumes and mass production quantities of finished metal parts. The high-quality tooling involved also ensures that any unit of parts, from thousands to millions, can be economically made before replacement is required. Consequently, die casting will achieve a lower cost-per-unit part when carrying out a mass production run. The uniformity of mass-production die casting parts is exceptional.

· Complex Geometry and Design Versatility

Die casting operations can achieve complex shapes and geometries, and parts with thin walls seamlessly with little or no need for post-machining on ejection.

· Part Size and Speed

Die casting is especially suited for making metal parts with larger dimensions that would be slower and costlier to make using CNC machining. With the average cycle time for a die casting process around 2 to 60 seconds, die casting is quicker for applications with high turnaround and lead-times.

· Custom Surface Finishes

Aluminum extrusions can be finished with several customized touches to optimize your part functionality and product needs, allowing you to complete your piece in bespoke specifications.

Die Casting Applications

 

First Part die casting operations have versatile applications across several industries. The speed, precision, and dimensional accuracy make our services an excellent choice for:

· High-precision end-part production

High pressure Die casting accounts for over 50 percent of all metal part production. It is well suited for making parts with great detail, tight tolerances, and excellent dimensional stability.

Die casting also finds wide application in casting metal parts where excellent surface finish and texture is crucial to usage and performance.

· Low density

· High castability

· Cold-chamber process

· High dimensional stability

· Excellent thermal and electrical conductivity

· Good corrosion resistance

· Good strength-to-weight ratio

· Can be highly polished

· Ideal for complex geometries

Sanding is a surface smoothing and polishing operation done with the aid of sandpaper or sand. The size of the pores in the sandpaper determines the type of smoothness achievable.

· Sanding

· Painting

Cast parts may be masked and spray-painted to any color with automotive-grade paints after sanding and polishing have been carried out to smoothen the surface.

· Powder coating

Cast parts may be coated with colored powder paint after fabrication to deliver a dry, melted, and hardened finish to a piece. Very suitable for workpieces that need textures that may not be achievable using wet painting.

· Polishing

Used for creating high-quality surface finish in cast parts. Before polishing, parts should be sanded and smoothed to ensure that the final surface looks and fees as intended. 

· Anodizing

Anodizing is primarily used to increase the thickness of the natural oxide layer on your part's surface. It is prevalent for electronic products made from magnesium, aluminium, and other metal parts. It can be used for decorative, anti-corrosion, heat dissipation, or surface hardness treatments. Anodizing is also very ideal as a priming and painting surface treatment. At First Part, we offer Type 1, 2, and 3 anodizing. We also have chemical film anodizing options.

· CNC machining

We use CNC machining processes as a finishing technique to convey details (etching and engraving) onto your parts' surface.

Can't find the desired finish? Click here to go to our finishing page and learn more about our array of finishing options in detail. We also offer custom finishing touches to help you achieve the desired finish or finishes for various parts. 

 

Cost-effectiveness and Turnaround

Our services ensure cost-effectiveness and quick turnarounds for low-volume and mass manufacturing. Through budget and design optimization, First Part can make your past at competitive market rates.

Capacity and Network

Excellent in-house capacity and capabilities, guaranteeing that your parts are made from top quality from start to finish. Enjoy non-disclosure agreements and take advantage of our network of over 20 CNC machining centres to manufacture parts home and abroad.

 

FAQs  Die Casting

 

1. Why choose die casting above CNC machining and other techniques?

The cost per unit part, larger achievable dimensions (size), and high tensile strength all make casting preferable to other techniques for creating high-quality metal parts. Some other advantages include the excellent surface finish and complex geometries that can be made with die casting.

2. What makes First Part die casting unique?

With over a decade of metal casting production, our engineers are skilled and versed in making the finest cast parts from aluminium, zinc, magnesium, and even copper.

With over a decade of metal casting production, our engineers are skilled and versed in making the finest cast parts from aluminum, zinc, magnesium, and even copper.

3. Can die casting be combined with other techniques?

Yes. As a one-stop-shop, First Part can combine die casting with other techniques like CNC machining to include extra features like engraving onto castings.


Die Casting Services || First Part

 

Accuracy, Speed & Volume

 

First Part offers professional one-stop die casting services for making large units of high-quality metal parts with excellent strength, geometry, and finish through the use of reusable molds. Our die casting services are very robust, encompassing a range of operations from mold making, part casting, machining, polishing, and other finishing options.

 

Our service is a guarantee of quality from start to finish; our quality control and assurance units ensure your raw materials' quality while casting parameters are fine-tuned for optimal quality in your finished parts. With First Part, you can rely on the quality of excellence from our professional service and cost-effective rates for making your casted parts with speed and precision.

· Low-pressure Die Casting

Low-pressure die casting is a metal casting technique used for symmetric aluminium components. While its application is on the rise, it encompasses around 20% of all the total production. Low-pressure die casting is often used for making larger, non-critical parts that do not demand many details.

· Vacuum Die Casting

Vacuum die casting also called vacuum pressure casting, is a metal casting technique for making casts with improved strength. The process uses a vacuum system that reduces turbulence and limits the volume of gases in the process. This, in turn, significantly minimizes the potential of having a porosity defect.

· Cold-chamber Die Casting

The cold-chamber die casting process is designed more around reducing machine corrosion rather than production efficiency. It is used for very corrosive applications and cannot be carried out in a hot-chamber because it would damage the pumping system. Cold-chamber casting is used with metals with high melting temperatures. The most common materials used in cold casting include aluminum and aluminum alloys, brass, and magnesium.

· High-pressure Die Casting

High-pressure die casting is a metal manufacturing technique that is carried out under high pressure and high temperature. High-pressure die casting is the most common form of die casting, encompassing over 50% of all light-alloy cast parts. It has the most comprehensive application and is particularly excellent when making metal parts with detailed geometry and those requiring strict tolerance.

· Hot-chamber Die Casting

The Hot-chamber die casting process, also called gooseneck casting, is used when casting metal alloys with low melting temperatures and high fluidity. These alloys include zinc, magnesium, copper, tin, and lead. It is suitable for high volume production at faster rates than the cold-chamber casting. However, the design of the process makes it more corrosion-susceptible.

Generally, a die casting operation will follow five primary sequences of operations. These include:

1. Camping

The die casting process begins with the clamping of either half of the die. First, the die half is cleaned and lubricated to facilitate ejection. After each half has been greased, the halves are attached inside the die casting machine, closed and secured together.

2. Injection

After the die halves have been clamped with sufficient force to held them shut, the injection of the molten material commences. The molten metal is kept at the process temperature in a furnace. It is then transferred into the chamber and injecting it into the die.

 

The die transfer method will depend on whether the hot or cold chamber method is being used. Once transferred, the material is forced into the die at high pressure. Process control is essential to ensure that the injection time is short, and the material fills the channels and cavities before solidification begins. 

 

Once filled, the next phase of cooling commences.

3. Cooling

The die casting process begins with the clamping of either half of the die. First, the die half is cleaned and lubricated to facilitate ejection. After each half has been greased, the halves are attached inside the die casting machine, closed and secured together.

The die casting process is fairly robust. High-quality metal parts can be made with several techniques, including pressure and vacuum die casting. At First Part, our die casting processes support an array of materials. Depending on the metal's melting point, the geometry, and part size, we can run both hot chamber, and cold chamber die casting to optimize and deliver superior results with the applicable method.

6. Finishing

The finishing process is an aftermath of the casting operation. Die casted parts can be finished in a wide array of options. Depending on the end-use, parts may be left "as manufactured," revealing tool and cast marks. They may also be polished, plated, anodized, or brushed. 

Our Die Casting Process

 

4. Ejection

After the cooling time is elapsed, the die halves are opened, and the ejection mechanism commences to push out the casting. Ejection must be done with sufficient force as casted parts will usually shrink and adhere to the die. After the casting has been ejected, the die is clamped shut in preparation for the next injection cycle.

5. Trimming

The ejected part will have some excess materials arising from flash. The solidification process of the molten material along the die channels will also cause extra materials to attach to the casting. These material excesses must be trimmed to ensure that the final part is within the dimensions and specifications. Any scrap material removed from the casting can be reconditioned and recycled for reuse in the die casting process.

At First Part, we understand all the factors that go into producing a high-quality casting. This is why we ensure the use of stringent quality control systems and processes to optimize your production from tooling to final part casting. Our die casting process consists of 7 main stages, with an average cycle time between 3 – 60 seconds. On receiving your order, We shall proceed with the following operations:

· Perform a free Design for manufacturing (DFM) review

 

· Run a material quality evaluation for compliance evaluation

 

· Commence die casting operations

 

· Engage the part in any post-processing (if need be), to capture all desired details

 

At First Part, our die casting offerings are robust and affordable. From the tight tolerances and dimensional stability that our castings possess to the excellent surface finish and complex geometries, the  advantages of metal die casting are:

· Heat treat the mold to temper them

 

· Fabricate your casting tools using our CNC machine tools, capturing the tiniest details in the core and cavity

 

Die Casting Operations

· Use our in-house process control systems to monitor and optimize your production

 

· Perform final evaluation and quality control to ensure finished casting meet the specified dimensions and surface           finishes/details.

· Minimal Assembly

Assembly features like holes, bosses, snap fits, and more can be incorporated into the mold design, limiting the need for post-machining or post-processing.

· Enclosures and Housings

Die casting is widely used for making housing and thin-walled enclosures. Most metal casings and enclosures for consumer electronics are often die-casted. Parts like aerospace or automobile components, including gears, bushings, valves, pumps, engine blocks, pistons, and cylinder heads, are usually made with die casting.

· High-volume Manufacturing

Die casting is the best solution for making mass production units of metal parts. The tooling cost involved can be spread across the hundreds of thousands of parts manufacturable from the tool, thereby lowering the cost-per-part.Die casting is also suitable for making large parts that may be impossible or take longer with machining.

 

· Aluminium

· Magnesium

· Low density

· Excellent strength-to-weight ratio

· Suitable for high-performance applications

· Excellent machinability post-die casting

· Compatible in hot and cold-chamber processes

· Zinc

· High ductility

· High density

· Great impact resistance

· Low cost

· Easiest castability

· Excellent surface properties

· Low melting point and longer life span

· Hot-chamber process

· Avoid corrosion by coating

· Can make parts with very thin walls

· suitable for for plating

· Standard/As manufactured

Casted parts are left as manufactured. There may be visible tooling marks on the part.

· Painting

Electroplating (such as Nickel plating) is used to improve the strength and durability of castings.

· Custom

An array of custom finishes are also available for your part, depending on the end-use part's material and purpose.

4. What is the minimum order quantity?

Generally, we have no minimum order quantities for most manufacturing operations. We can produce casted parts from 10 units and above.

5. What is the technical Specifications?

Our die casting operations can manufacture small to large part sizes with tight tolerances and high precision.The casting's overall dimension and quality depend on the material, part size, surface finish, and tolerance.

Parameter

Standard

Possible

Shapes

Cylindrical

Cylindrical thin-walled parts

Flat

Cubic thin-wall parts

Complex geometries

Cubic
Complex thin-walled parts  

Materials

Lead, Aluminium Copper
Tin, Zinc, Magnesium

Part size

0.5 ounces to 500 pounds 

0.5 ounces to 500 pounds

Part size

+/- 0.0015 inches

+/- 0.0005 inches

Quantities

1,000 – 1,000,000

1,000 – 10,000,000

Wall thickness

0.05 – 0.5 inches max

0.015 to 1.5 inches max

Surface finish

30 – 65 microinches (uin)

15 – 120 microinches (uin)

 

Material Options

 

First Part die casting services are used to make high-quality cast parts from metals and metal alloys. The most popular material options include:

Die Casting Service

Industries

 

Die casting is widely coveted for the low cost-per-unit advantage. This makes it suitable for production in some of the most popular industries. Some of the most popular sectors using die casting to create high-quality metal parts include:

 

Low Volume Production

Sheet Metal

Fabrication

Plastic Injection

Molding

Learn more about our other capabilities  

Why Choose Us

 

With over ten years' experience in die casting and general machining services, First Part offers one of China's best metal casting and finishing services. Here's why:

Request A Quote

 

Ready to get started? Contact us with details of your project to take advantage of our automated electronic quoting service, design verification process and excellent customer feedback program. With an extensive amount of finishing options to compliment a wide range of material types, over 100 CNC machining centres and deeply-rooted industry experience, Firstpart is always willing to collaborate and deliver functional end-use parts with quality you can trust every time.

 

Click here to get in touch with us and get a free quote now!