Die Casting Process
Die casting is the manufacturing process of choice when producing high volumes of relatively complex metal parts and is widely used due to its versatility, reliability, and accuracy. Die casting eliminates all or most secondary operations needed to make a metal part; however, post-machining is common to meet tighter critical-to-function tolerances. Die casted parts can also be post-processed in any finish their respective CNC machined counterparts can.
Like injection molding, die casting requires the fabrication of a mold tool—called a die—that can have one or multiple cavities. The process works for softer alloys, including aluminum and zinc alloys, due to their relatively lower melting temperature. Die casting works by injecting molten metal into a die cavity, which takes the shape of the part and hardens into place before removal. Depending on the project scope, die casting can be low- or high-pressure, using a ladle or plunger to deposit metal. Die casting can produce highly complex, tight-tolerance parts in a repeatable manner at very high production volumes. Modern methods such as squeeze casting and semi-solid metal casting produce high-quality parts for nearly every industry. Die casting companies often specialize in aluminum or zinc; aluminum makes up roughly 80% of die cast parts.
Our project managers and experts personally review and manually quote each die casting project to ensure we meet your unique needs while providing a fast and easy manufacturing experience.
Die Casting With Artemis 3D
From quote to production—our team and platform guide you through tooling and delivery.
Start A Quote
Upload your files to the Artemis 3D Quote Engine and configure your project. Our team will consult with you to ensure your specifications, lead time, and price fit your project needs. We will provide a DFM report for approval before kicking off tooling.
Sample Approval
Once your project is kicked off we will build a high-quality die. After the tooling is created we will send out part samples, called T1s, for approval.
Production Begins
Once satisfied with your samples, we move forward with production and deliver the parts. Artemis 3D handles supplier management and logistics throughout the process. You own your tooling and can easily re-order as needed to meet demand.
Types of Die Casting
Artemis 3D partners with die casters that use the latest die casting machines and technology. Our offering focuses on the two leading types: hot chamber and cold chamber casting. Both can produce parts with complex geometry, close tolerances, and robust mechanical properties.
Hot Chamber Die Casting
Also known as gooseneck casting, hot chamber die casting is the most popular process. It is optimal for lower melting point alloys such as zinc, magnesium, and lead. A holding pot is filled with metal and heated until molten. A gooseneck forms a holding chamber and a nozzle-like pathway to the die cavity. A plunger fills the chamber from the pot, then lowers to force molten material up the gooseneck into the die. The mold is held under pressure while the metal cools; the dies open and the casted piece ejects via ejector pins.
Cold Chamber Die Casting
The cold chamber remains at room temperature with no holding pot. Metal is melted in a separate furnace and deposited into the shot chamber by ladle. The mold connects directly to the shot chamber; a ram (not a plunger system) forces molten metal into the mold and holds it under high pressure while the metal solidifies. This type is suitable for higher melting temperature materials such as aluminum.
Metal Materials for Die Cast Parts
The material you choose depends on your intended use. Cast aluminum parts are common in aerospace or automotive where corrosion resistance and weight reduction matter. If you have a specific material request, let us know.
Aluminum Die Casting
Aluminum alloys are the most widely used for die cast parts. Due to the comparatively higher melting point, aluminum die casting typically uses cold chamber casting. Cast aluminum offers great strength-to-weight ratio, dimensional stability, and diverse finishing options. Characteristics: withstand high operating temperatures, corrosion resistance, good stiffness, high thermal and electrical conductivity.
Alloys we offer:
- A360.0
- A380.0
- A383.0 (ADC12)
- A413.0
Zinc Die Casting
Zinc is the easiest to cast among die casting metals and is typically used in hot chamber processes. Molten zinc has exceptional casting fluidity and a lower melting point. Its strength and stiffness allow thinner walls and highly detailed features with tight tolerances. Fastest production rates of the die casting materials. Characteristics: impact strength, high hardness, great stability, high-quality surface finish, easily plated, low melting point.
Alloys we offer:
- Zamak 2 (ZA-2)
- Zamak 3 (ZA-3)
Available Die Casting Finishes
Standard (As-Cast)
Zinc and aluminum zinc parts can be left as-cast. Aluminum parts must be coated for corrosion resistance. As-cast zinc surface finish is commonly 16–64 microinch Ra.
Bead Blasted
Smooth, matte appearance.
Anodized (Type II or Type III)
Aluminum; Type II for corrosion resistance, Type III for wear-resistant layer. Not electrically conductive.
Powder Coating
Electrostatically sprayed powder, baked. Strong, wear- and corrosion-resistant; wide color range.
Wet Painting
Wide variety of paint formulations and colors.
Plating
Electroless nickel, nickel, brass, tin, chrome, chromate, Teflon, silver, gold.
Chemical Film
Chromate conversion coat on aluminum; corrosion protection, paint adhesion; electrically conductive.
Media Tumbled
Vibratory media tumbling to remove sharp edges and smooth surfaces.
Custom
Submit an RFQ for other finishing processes.
Applications of Die Casting
The versatility and high production potential of die casting enable it for various applications and industries. Die casting is well suited for products that are small to medium in size with complex features. Examples include consumer and industrial products, automotive parts, aerospace components, and medical device parts. Die casting is a great option when you need high-volume metal parts that may be too large for similar high-volume processes such as Metal Injection Molding (MIM).
- Aerospace & Automotive Components
- Connector Housings
- Pumps and Plumbing Fixtures
- Outdoor Lighting
- Gears
- Appliances and Lighting
Die Casting Advantages and Disadvantages
Advantages
Complex Geometry
Die casting can reliably produce custom die cast parts with thin walls and challenging geometry that is durable and dimensionally stable.
Strength
Metal die castings are typically stronger than plastic injection molded parts and more resistant to high temperatures. Aluminum offers exceptional strength-to-weight ratios.
Precision
Typical tolerances +/-0.003"–0.005" per inch; can go as tight as +/-0.001" depending on specifications, part geometry, and material.
Custom Finishes
Smooth or textured surfaces, paints, and plating. Finishes protect from corrosion and improve cosmetic appearance.
Disadvantages
Tooling Cost
Per-piece cost is relatively low, but tooling dies and maintenance can require a high initial investment.
Not for Low Quantities
Due to upfront tooling costs, die casting is not economical for low-volume runs. Consider die casting for quantities greater than 1,000.
Lead Times
DFM, tool design, tool manufacture, and samples often take multiple weeks before production. One of the slower processes to ramp up.
Our team works with you throughout the process and offers suggestions and options to provide the best possible turnaround while meeting your unique needs.
Why Choose Artemis 3D for Online Die Casting Services?
Endless Options
Millions of combinations of materials, finishes, tolerances, markings, and certifications.
Easy to Use
Get started with our platform; our experts manage the project from locating the right manufacturing partner to delivery logistics.
Vetted Network
ISO 9001:2015, ISO 13485, AS9100D certified. Only the top shops that apply become suppliers.
Built-In Tool Management
Our platform has built-in features that make managing tooled projects easier, with greater transparency into production. Find all your tooling quotes and orders in one place with your Tool Library. From there you can explore tool detail pages covering current status, milestones, tool specifics, and activity. You can also easily find and contact the team member assigned to your project, no matter the phase.
- Better management of tooled quotes & orders
- Tool organization & categorization
- Detailed status updates & tooling information
- Easily connect with experts
- Project transparency
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