English 
Pressure die casting is a metal casting process characterized by the application of high pressure to the molten metal inside the mold cavity. The mold is usually machined from a hard, rigid alloy. The process of casting is somewhat similar to injection molding. We classify machines into two different types depending on the type of it, hot chamber dies casting machines and cold chamber die casting machines. The difference between these two types of machines is the amount of force they can withstand. Usually, they have a pressure range between 400 and 4000 tons.
Pressure Die Casting is a precise and efficient metal casting process that uses high pressure to inject molten metal into a reusable steel mold, known as a die. This process is widely used for producing high-volume, dimensionally accurate, and durable metal parts with excellent surface finishes.
The process begins with creating a steel die (mold) that defines the part’s shape. The die consists of two halves — a fixed half and a movable half — which open and close during each casting cycle. Proper mold design ensures accuracy, smooth ejection, and long tool life.
Metals such as aluminum, zinc, or magnesium are melted in a furnace until they reach a precise pouring temperature. Maintaining the right temperature ensures a stable flow and consistent part quality.
The molten metal is injected into the die cavity under high pressure (ranging from 1,500 to over 30,000 psi). This pressure forces the metal to fill every intricate detail of the mold, ensuring tight tolerances and smooth surfaces.
Once the cavity is filled, the metal cools rapidly inside the die. High pressure is maintained during cooling to prevent shrinkage and porosity, resulting in dense and strong castings.
After the metal solidifies, the die halves open, and ejector pins push the finished casting out. The part is then trimmed to remove excess material like gates and runners.
Post-processing may include polishing, powder coating, plating, or machining to achieve the final appearance and dimensions. Each casting is inspected to ensure it meets Team-MFG’s strict quality standards.
Pressure die casting is a high-precision metal forming process that involves injecting molten metal into a steel mold under high pressure. This technique is ideal for producing complex, high-strength components with excellent surface finishes. The choice of material significantly impacts the performance, durability, and cost-effectiveness of the final product. Below, we explore the most commonly used materials in pressure die casting: aluminum, zinc, and magnesium alloys.
Aluminum alloys are among the most popular choices for pressure die casting due to their lightweight nature and excellent corrosion resistance. They are particularly suited for applications in the automotive, aerospace, and electronics industries.
Common Aluminum Alloys:
A380: Offers high fluidity and is commonly used for automotive parts and consumer electronics.
ADC12: Known for its excellent castability and is widely used in the automotive industry.
Advantages:
Lightweight, reducing overall product weight.
High resistance to corrosion, enhancing product longevity.
Good mechanical properties, suitable for structural components.
Applications:
Engine components
Transmission housings
Electronic enclosures
Lighting fixtures
Zinc alloys are favored for their excellent dimensional stability and ease of casting. They are ideal for producing small to medium-sized parts with intricate details.
Common Zinc Alloys:
Zamak 3: Offers good strength and is widely used for decorative parts.
Zamak 5: Provides higher strength and is suitable for structural components.
Advantages:
Excellent fluidity, allowing for complex shapes.
High dimensional stability, ensuring tight tolerances.
Good corrosion resistance, suitable for outdoor applications.
Applications:
Automotive parts
Electronic connectors
Locks and latches
Hardware components
Magnesium alloys are the lightest structural metals available, offering an excellent strength-to-weight ratio. They are commonly used in industries where weight reduction is critical.
Common Magnesium Alloys:
AZ91D: The most widely used magnesium alloy for die casting.
AM50: Offers improved ductility and is used in automotive applications.
Advantages:
Lightweight, reducing overall product weight.
Good strength properties, suitable for structural applications.
Excellent heat dissipation, beneficial for electronic components.
Applications:
Automotive interior parts
Portable electronic devices
Sporting equipment
Aerospace components
| Criteria | Aluminum Alloys (A380, ADC12) | Zinc Alloys (Zamak 3, Zamak 5) | Magnesium Alloys (AZ91D, AM50) |
|---|---|---|---|
| Density / Weight | ★★☆ – Lightweight, ideal for reducing overall part weight | ★★★ – Heavier than aluminum but stable | ★★★★ – Lightest structural metal available |
| Strength-to-Weight Ratio | ★★★ – Good balance of strength and weight | ★★☆ – Moderate strength | ★★★★ – Excellent ratio for lightweight parts |
| Corrosion Resistance | ★★★★ – Excellent, especially with surface treatment | ★★★ – Good, suitable for indoor/outdoor use | ★★☆ – Requires coating or plating for protection |
| Casting Precision | ★★★ – Suitable for medium-to-complex parts | ★★★★ – Excellent for fine details and thin walls | ★★☆ – Moderate; best for larger or simple shapes |
| Thermal Conductivity | ★★★★ – Good heat dissipation | ★★☆ – Moderate | ★★★★ – Excellent, great for electronics |
| Machinability | ★★★ – Easy to machine and finish | ★★★★ – Very good; supports tight tolerances | ★★☆ – More challenging to machine |
| Cost Efficiency | ★★★★ – Economical for high-volume production | ★★★ – Affordable for small to medium runs | ★★☆ – Higher material cost |
| Common Applications | Automotive housings, electronic enclosures, lighting parts | Hardware, locks, decorative components | Aerospace, electronics, portable devices |
| Best For | When you need lightweight, corrosion-resistant, and durable parts | When you need precise, detailed, and dimensionally stable parts | When weight reduction and strength are top priorities |
Hot chamber die casting and cool chamber die casting are the two types of pressure die casting
Hot chamber dies casting, sometimes referred to as gooseneck casting. It has a pool of liquid, semi-liquid metal in a molten state, which fills the mold under pressure. At the beginning of the cycle, the piston of the machine is in a contracted state and the molten metal is ready to fill the gooseneck section. The rise of the pneumatic or hydraulic piston squeezes the metal and fills the mold.
The advantage of this system is that it has a very high cycle speed (about 15 to 16 cycles per minute) and is easily automated. The process of melting the metal is also easy. The disadvantages include the inability to die-cast metals with high melting points, as well as the inability to die-cast aluminum, which would bring out the iron in the melt cell. As a result, hot chamber dies casting machines are generally used for alloys of zinc, tin, and lead. However, hot chamber die casting is not able to die-cast large castings, and its casting is generally for small castings.
When casting metals that cannot be used in the hot chamber die casting process (such as large castings) then cold chamber dies casting can be used (including aluminum, magnesium, copper, and zinc alloys with high aluminum content). In this process, the metal is first melted off in a separate crucible. A certain amount of molten metal is then transferred into an unheated injection chamber or injection nozzle. The metal is injected into the mold by hydraulic or mechanical pressure. However, the biggest disadvantage of this process is the long cycle time due to the need to transfer the molten metal into a cold chamber for freezing. There are two types of cold chamber die casting machines. There are vertical and horizontal machines. Vertical casting machines are usually small machines, while horizontal casting machines are available in various models.
When it comes to die casting, two methods dominate the industry — Cold Chamber and Hot Chamber Die Casting. Both processes create precise, durable metal parts, but they differ in materials, speed, and performance. Understanding these differences helps you choose the right solution for your product design and manufacturing goals.
| Aspect | Hot Chamber Die Casting | Cold Chamber Die Casting |
|---|---|---|
| Metal Type | Zinc, Magnesium | Aluminum, Copper, Brass |
| Cycle Speed | Very Fast | Moderate |
| Melting Point | Low | High |
| Machine Setup | Injection system immersed in molten metal | Molten metal ladled into chamber |
| Production Volume | High-volume, small parts | Medium to large parts |
| Part Strength | Good | Excellent |
| Cost Efficiency | Cost-effective for small parts | Better for large, complex parts |
If your project demands high-speed production and uses low-melting alloys like zinc or magnesium, Hot Chamber Die Casting is the most efficient choice.
However, if you need strong, heat-resistant aluminum parts or large, structural components, Cold Chamber Die Casting delivers superior performance and durability.
TEAM MFG is a rapid manufacturing company specializing in ODM and OEM. We provide quality service to our customers in strict accordance with ISO guidelines. Since 2015, we have been offering a range of rapid manufacturing services such as additive manufacturing services, CNC machining services, injection molding services, pressure dies casting services, etc. to help you with your small-batch manufacturing needs. Over the past 10 years, we have received a lot of positive feedback from our happy customers. We believe that “Product quality is the lifeblood of TEAM MFG”. Contact Us Today!
