Custom High Pressure Die Casting Services

TEAM MFG provides high pressure die casting (HPDC) solutions worldwide starts from 2017. Using advanced die casting technology, we manufacture high-quality aluminum and zinc die cast parts that meet the strictest industrial standards.

Our custom die casting services are designed for customers who demand precision, durability, and cost-efficiency. Whether you need low-volume prototypes or high-volume production, TEAM MFG delivers consistent, tight-tolerance parts with excellent mechanical strength and surface finish.

As a leading die casting manufacturer in China, TEAM MFG offers comprehensive support — from design optimization and mold making to casting, finishing, and quality inspection. Our engineering team ensures every part meets your exact specifications and performs reliably in real-world applications.

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What is High Pressure Die Casting

High Pressure Die Casting (HPDC) is a manufacturing process used to produce metal parts with complex shapes, tight tolerances, and excellent surface finishes. In this process, molten metal—usually aluminum or zinc—is injected into a steel mold cavity under very high pressure, typically between 1,000 to 20,000 psi. The metal quickly solidifies, forming a dense and durable casting that requires little or no machining.

This process is ideal for producing precision metal components for industries such as automotive, aerospace, electronics, and industrial equipment. It is highly versatile—perfect for both low-volume custom production and mass production runs where tight tolerances and consistent quality are required.

Thanks to its efficiency, accuracy, and excellent repeatability, high pressure die casting has become one of the most widely used metal casting methods for creating durable, high-performance parts.

How Does High Pressure Die Casting Work？

High pressure die casting process step by step

Prepare-the-Mold

Prepare the Mold

The first step in the high pressure die casting process is the preparation of the mold, also known as the die. The die is a precision-engineered steel mold that defines the final shape and dimensional accuracy of the cast part. It typically consists of two sections — the cavity die and the core die — which close tightly to form the mold cavity where molten metal will be injected.

Before casting begins, the die casting mold is preheated to a controlled temperature. This step is crucial to ensure smooth metal flow, uniform filling, and proper solidification, reducing defects such as cold shuts or porosity. A well-prepared mold ensures consistent part quality and extended mold life, which are key advantages in high pressure die casting production.

Inject the Material

Once the high pressure die casting tooling is completed, the next step is to mount the die onto a high pressure die casting machine and inject molten metal into the cavity under controlled pressure. This is one of the most critical stages of the die casting process, as it determines the density, surface quality, and dimensional accuracy of the finished parts.

Depending on the type of alloy used, the injection process can be performed using two primary methods: Hot Chamber Die Casting and Cold Chamber Die Casting.

Inject-the-Material

Part-Ejection

Part Casting

After the molten metal solidifies inside the mold and takes the exact shape of the cavity, the next stage in the high pressure die casting process is part ejection. Once the casting has cooled to the required temperature, the die is carefully opened, separating the cover die and ejector die.

Ejector pins are then activated to push the finished high pressure die cast part out of the mold cavity. This step must be performed with precision and controlled process parameters to ensure the part is released smoothly without deformation or surface damage.

Proper ejection timing, mold temperature, and pin positioning are essential to maintaining the dimensional accuracy, surface finish, and structural integrity of each casting.

Trim the Excess Material

Once the die cast part is ejected from the mold, it often includes a small amount of excess material known as flash. This flash forms along the parting line where the two halves of the die meet.

The trimming process removes this unwanted material to achieve the final shape and precise dimensions required for each component. Trimming is a critical finishing step in high pressure die casting because it ensures that every part meets tight tolerances, smooth edges, and exact specifications.

Trim-the-Excess-Material

TEAM MFG - Your Trustful Die Casting Manufacturer in Chiina

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High Pressure Die Casting Capabilities at TEAM MFG

Providing 3D files / Simply offers a phyisical sample for rapid design validation or reverse engineering

1. DFM suggestions to shoot down potential issues.
2. Different grades of aluminum alloy available.
3. Precise prototypes and low volume casting available.
4. Tooling made in harden H13 steel.
5. Post CNC machining to acheive tight tolerance.
6. Valued-add post finish available.

High Pressure Aluminum Die Casting

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1. High pressure die casting simulation to optimize designs.
2. Zinc3 and Zinc5 to cast detailed features.
3. NO MOQ, good to process low volume casting.
4. Tooling made in harden H13 steel.
5. Precise CNC machining for tight tolerance dimensions.

6. A series of surface treatments available.

High Pressure Zinc Die Casting

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Mold Tooling Steel

Our mold tools are usually made in H13 tool steel with a Rockwell hardness of 42-48. 2. Specialty steels are available upon request.

Different metals are available for casting. Your choice of materials may depend on cost, weight and performance.

Maximum Part Size: 1200x1000x500mm
Minimum Part Size: 5x5x5mm

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Die Casting Aluminum
Aluminum is ideal for strong, lighweight yet complex geometries. It can also be highly polished. Our alloys include ADC12, A380, ADC10 and A413.

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Die Casting Zinc
Zinc is the least expensive but is good for plating. Available alloys are Zinc #3 and #5.

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Post Machining

Die casting parts post-machining refers to additonal machining processes to achieve precise dimensions, tight tolerances, or smooth surface finishes that we can't reach only by die casting process.

In order to achieve an accurate process and high precise die casting parts, TEAM MFG invests a series of advanced CNC machines and tools. Combining with the rich CNC machining experience, we know how to make jig fixture to shorten machining time and guarantee the post machining accuracy. Therefore you can find a competitive price and a short lead time solution under one-roof at TEAM MFG.

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3-axis, 4-axis, 5-axis CNC Post-Machining
Applied in the parts need tight tolerance, critical features, flatness, excellent surface finish. Typically, the cost of CNC post-machining is higher than traditional post-machining methods.

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Common Post-Machining Operations
Milling / Turning / Drilling / Tapping / Boring / Grinding / Deburring etc. There are common methods for die casting parts with loose tolerance / features.

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Surface Finishes For Your Casting Parts

Anodizing
Sandblasting
Polishing
Plating
Painting
Powder Coating
Silk Printing
Laser printing

Anodizing

It is a method for changing the surface chemistry of metals and other substrates. It protects against corrosion, enhances aesthetic qualities, resists scratching and is one of the most durable surface finishes available.
Sandblasting

It can remove paint, rust, and residue from oxidation from materials quickly and efficiently. Sandblasting can also be used to change the condition of a metal's surface, such as through removing scratches or casting marks. Sandblasting as a cleaning method has been widely used for over a hundred years.
Polishing

It is the process of creating a smooth and shiny surface by rubbing it or by applying a chemical treatment, leaving a clean surface with a significant specular reflection (still limited by the index of refraction of the material according to the Fresnel equations).
Plating

It is used to decorate objects, for corrosion inhibition, to improve solderability, to harden, to improve wearability, to reduce friction, to improve paint adhesion, to alter conductivity, to improve IR reflectivity, for radiation shielding, and for other purposes.
Painting

It is most commonly used to protect, color, or provide texture to objects. Paint can be made or purchased in many colors—and in many different types, such as watercolor or synthetic.
Powder Coating

It provides a more durable finish than liquid paints can offer, while still providing an attractive finish. Powder coated products are more resistant to diminished coating quality as a result of impact, moisture, chemicals, ultraviolet light, and other extreme weather conditions.
Silk Printing

It is the process of pressing ink through a stencilled mesh screen to create a printed design. It’s a popular technique used in a whole range of different industries, so even if you've never heard of the term before today, it’s likely that you’ve worn or used a screen-printed product at some point without even realising.
Laser printing

It is an electrostatic digital printing process. It produces high-quality text and graphics (and moderate-quality photographs) by repeatedly passing a laser beam back and forth over a negatively charged cylinder called a "drum" to define a differentially charged image.

Let the Number Speak for Us and Our Clients

We are in
the industry

12

Years
We have Clients in

73

Countries
Successful work with

1302

Clients
Successful completed

15301

Projects

High Pressure Die Casting Advantages And Disadvantages

Advantages

Higher Production Efficiency
At TEAM MFG, our high pressure die casting process enables rapid and efficient production of metal parts, making it ideal for high-volume manufacturing. With advanced die casting machines and automated systems, we achieve short cycle times and consistent output, helping customers reduce lead time and production cost.
Superior and Consistent Quality
Our aluminum and zinc die cast parts are produced with tight tolerances and excellent repeatability. Every component meets strict dimensional and surface finish requirements, ensuring reliable quality that exceeds industry standards. This makes TEAM MFG a trusted partner for industries that demand precision and durability.
Capability to Produce Thin-Walled Components
High pressure die casting allows us to manufacture thin-walled and lightweight parts without sacrificing strength. This capability is especially valuable for automotive, aerospace, and electronics applications where weight reduction and design flexibility are critical.
Complex and Intricate Designs
The versatility of the high pressure die casting process makes it possible to produce complex geometries, fine details, and integrated features directly in the mold. This reduces the need for secondary machining and enables cost-effective production of sophisticated designs.
Long-Lasting and Cost-Effective Tooling
Our die casting molds are built from high-grade tool steel that can withstand extreme temperatures and pressures. These durable tools ensure long service life and stable quality over thousands of cycles, offering excellent value for large production runs.

Advantages

Disadvanges

Disadvantages

Higher Initial Tooling and Setup Costs
High Pressure Die Casting requires precision-engineered steel molds and advanced casting machines. The tooling and setup costs can be significant, especially for small production runs. However, the investment is cost-effective for high-volume manufacturing where the per-part cost decreases over time.
Limited to Certain Metals and Alloys
HPDC is best suited for non-ferrous metals such as aluminum, magnesium, and zinc alloys. It is not ideal for ferrous metals like steel or iron due to the high melting temperatures, which can damage the mold or reduce tool life.
Porosity in Cast Parts
During the injection process, air entrapment can occur, leading to porosity inside the casting. This may affect the mechanical strength and pressure tightness of the part, which makes HPDC less suitable for applications requiring leak-proof or high-stress components without additional post-processing.
Limited Wall Thickness and Part Size
While HPDC excels at producing thin-walled parts, it has limitations when it comes to large or very thick components. Thick sections may not solidify evenly, leading to internal stresses or dimensional inaccuracies.
Post-Machining May Be Required
Even though HPDC produces precise components, some machining operations may still be needed to achieve tight tolerances, remove flash, or finish critical surfaces — adding extra time and cost.
Mold Wear and Maintenance
The high injection pressures and molten metal flow can accelerate mold wear over time. Regular maintenance and refurbishment of dies are required to ensure consistent quality and long tool life.

Why Us For Pressure Die Casting

Choosing the right high pressure die casting manufacturer is critical to achieving top-quality metal parts with reliable performance and cost efficiency. At TEAM MFG, we combine advanced manufacturing technology, professional engineering expertise, and strict quality control to deliver exceptional die casting services that meet global standards.

Advanced Die Casting Technology
TEAM MFG is equipped with state-of-the-art high pressure die casting machines capable of producing complex aluminum, zinc, and magnesium components with outstanding precision. Our advanced process control ensures consistent results, excellent surface finishes, and tight dimensional tolerances.
Experienced Engineering Team
Our professional engineering team has extensive experience in die design, mold flow analysis, and casting optimization. From concept to production, TEAM MFG offers expert design-for-manufacturing (DFM) guidance to ensure your parts are optimized for cost, quality, and performance.
Comprehensive In-House Capabilities
In addition to casting, we offer CNC machining, surface finishing, and assembly services, allowing us to deliver complete end-to-end manufacturing solutions. This integrated approach helps reduce lead times, minimize costs, and ensure consistent quality across all stages of production.
Strict Quality Control
Quality is at the heart of everything we do. TEAM MFG’s ISO 9001:2015-certified quality management system ensures every part is carefully inspected through CMM testing, X-ray analysis, and leak testing when required. We guarantee precision, consistency, and reliability in every project.

Trusted by Global Customers

TEAM MFG has been a trusted partner for customers across the USA and Europe, delivering high-quality die casting components for industries such as automotive, electronics, lighting, and industrial equipment. Our dedication to customer satisfaction and long-term collaboration makes us stand out among die casting suppliers in China.

High Pressure Die Casting Process Applicatoins

High Pressure Die Casting (HPDC) stands as a versatile and efficient manufacturing process, finding widespread applications across diverse industries.

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Automotive

The automotive industry is a primary beneficiary of High Pressure Die Casting due to its ability to produce lightweight yet durable components. The demand for such components has surged, driven by the need for fuel-efficient vehicles without compromising on strength.

This process facilitates the creation of intricate shapes and thin-walled sections, enhancing fuel efficiency. Aluminum, magnesium, and zinc alloys, with their favorable strength-to-weight ratios, are commonly employed in automotive HPDC. This aligns seamlessly with the industry's pursuit of sustainability, enabling substantial reductions in vehicle weight, contributing to lower fuel consumption, and reduced emissions. Looking for reliable aluminum high pressure die-casting auto parts manufacturers is important, TEAM MFG is a aluminum high pressure die-casting auto parts factory, contact us today for your upcoming projects!

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Aerospace

In the aerospace sector, precision and performance are paramount, making High Pressure Die Casting an integral part of manufacturing processes. Aircraft components demand materials that are lightweight yet possess high structural integrity.

Critical aerospace components like engine parts, airframe components, and structural elements benefit from HPDC's ability to create intricate and complex designs with precision. This ensures that aerospace manufacturers can meet the demanding specifications required for safe and efficient flight. The lightweight properties of materials produced through HPDC contribute to fuel efficiency, reducing operational costs and environmental impact, aligning with the industry's commitment to innovation and safety.

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Medical

In the medical field, precision, reliability, and biocompatibility are crucial, making High Pressure Die Casting a valuable tool in the production of various medical devices and equipment. The demand for complex designs and lightweight materials finds a suitable match in HPDC.
Medical equipment, such as diagnostic devices, patient monitoring systems, and imaging components, often requires intricate shapes and designs that are challenging to achieve through traditional manufacturing processes. HPDC addresses these challenges by providing a cost-effective and efficient method for producing such components.
Materials like aluminum, magnesium, and zinc, known for their biocompatibility and corrosion resistance, become preferred choices in medical HPDC. The lightweight nature of the produced components proves particularly advantageous in portable medical devices, enhancing their usability and maneuverability.

Looking for High Pressure Die Casting Companies

TEAM MFG is one of professional high pressure die casting companies who makes 10M+ Parts Manufactured up-to-date

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Videos of Our Daily Works

High Pressure Die Casting Case Studies

Our machines' high pressure die casting pressure range from 30 to 1000+ ton, we are able to make not only small size parts but also the large ones!

Pressure Die Casting

Aluminum Turbine

Front Cover
Pressure Die Casting

Aluminum Turbine

Rear Cover

Pressure Die Casting

Zinc Bracket
Pressure Die Casting

Aluminum Arm
Pressure Die Casting

Aluminum Case

30M+ parts manufactured to-date

The quality and detail that has been achieved has surpassed all my expectations. Absolutely amazing job guys!

Andrew

Andrew, Engineer of Home Tech Innovation

High Pressure Die Casting vs Low Pressure Die Casting

The main difference of high pressure die casting (HPDC) and low pressure die casting (LPDC)：

How they fill the mold and the resulting properties of the cast parts.

Pressure

HPDC uses high pressure (up to 150,000 kPa or 21,700 psi) to force molten metal into a mold, while LPDC uses low pressure (typically 20-100 kPa or 2.9-14.5 psi) to gently fill the mold from the bottom.
Mold Materials & Parts Materials

Mold Materials: HPDC typically uses metal molds, while LPDC can use various materials, including metal, sand, or ceramic.

Part Materials: Aluminum, magnesium, zinc, and copper alloys can be used in HPDC, while LPDC is commonly used with aluminum and magnesium alloys.
Production Volumes

HPDC can be applied in any volumes from small batch production to mass production, while LPDC is commonly used in low volume production.

Hot Chamber Die Casting vs. Cold Chamber Die Casting

In High Pressure Die Casting (HPDC), molten metal is injected into a steel mold under high pressure to produce precise, high-strength parts. Depending on the type of alloy used and production needs, manufacturers typically choose between Hot Chamber Die Casting and Cold Chamber Die Casting. Each process has its own advantages and ideal applications.

Category	Hot Chamber Die Casting	Cold Chamber Die Casting
Melting Point	Low(Zinc, Magnesium)	High(aluminum, copper)
Cycle Time	Faster	Slower
Injection System	Immersed in molten metal	Separate from molten metal
Tool Life	Longer due to lower temperature	Shorter due to high temperature alloys
Applications	Small, thin-walled components	Large, strong structural parts
Surface Finish	Excellent	Good(many need post-finishing)

Which Process Should You Choose?

The choice between hot chamber and cold chamber die casting depends on your material selection, production volume, and part design.

Choose Hot Chamber Die Casting for smaller, detailed parts made from zinc or magnesium.
Choose Cold Chamber Die Casting for larger, high-strength aluminum or brass components.

FAQs

Can I fully customize my die casting parts?

Yes. TEAM MFG offers full customization, including design modifications, shapes, sizes, wall thickness, and surface finishes. Secondary processes like polishing, anodizing, powder coating, or plating are also available.
What is the typical production lead time?
- Prototypes: Usually ready in a few weeks, depending on complexity.
- Mass production: Efficiently completed in a few weeks to meet deadlines. Lead times may vary based on design, material, and order size.
Do you have a minimum order quantity (MOQ)?

TEAM MFG can accommodate small or large orders, making HPDC accessible for startups and large-scale industrial projects alike.
How do you ensure quality and precision?

We maintain strict quality control throughout the production process, using advanced machinery and testing equipment to ensure dimensional accuracy, surface finish, and material integrity.
Do you offer technical support or consultation?

Yes. Our experienced engineers provide design advice, material selection guidance, and technical support to optimize your parts for performance and manufacturability.

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