Die casting is a highly efficient metal casting process where molten nonferrous alloys are injected into precision-engineered steel molds under high pressure and rapid flow rates, enabling the rapid production of complex, high-quality components. The primary materials utilized in die casting include aluminum, magnesium, and zinc alloys, chosen for their excellent casting properties and structural qualities.
The molds, known as dies, are manufactured from hardened steel and designed with intricate cavities that replicate the final product’s shape. During the process, these dies are subjected to extreme temperatures and pressures, allowing for the creation of precise, dimensionally stable parts. Die casting predominantly employs non-ferrous metals such as zinc, copper, aluminum, magnesium, lead, pewter, and tin-based alloys. Depending on the alloy, either hot-chamber or cold-chamber die casting machines are used to facilitate the process.
Given the substantial initial investment in machinery and die manufacturing, die casting is most cost-effective when producing large volumes of parts. The process itself is straightforward, comprising mainly four key stages—mold creation, metal preparation, injection, and finishing—making it suitable for high-volume manufacturing of small- to medium-sized components. The end products are distinguished by their excellent surface finish and tight dimensional tolerances, making die casting a preferred method in various industrial sectors.