Why is it called die casting?

Die casting is named so because it involves the use of a metal mold, known as a die, into which molten metal is injected under high pressure. The term "die" refers to the mold or tool that shapes the metal into the desired form during the casting process.

Is high-pressure die casting for plastics?

No, highpressure die casting is primarily used for metals, not plastics. In this process, molten metal is injected into a die under high pressure to produce complex and detailed metal parts with high accuracy and surface finish. Plastics, on the other hand, are commonly processed using injection molding techniques.

What is the difference between low-pressure and high-pressure die casting?

The main difference lies in the pressure used to inject molten metal into the die. In low-pressure die casting, the metal is typically forced into the mold at a lower pressure, allowing for the production of larger and more massive parts. High-pressure die casting, as the name suggests, involves injecting molten metal at significantly higher pressures, resulting in the production of smaller and more intricate parts with finer details.

What is the difference between high-pressure casting and gravity casting?

The key distinction between high-pressure casting and gravity casting lies in the method of metal injection. High-pressure casting involves injecting molten metal into the die under substantial pressure, enabling the production of detailed and high-precision parts. In gravity casting, on the other hand, the molten metal is poured into the mold using the force of gravity, making it a more suitable method for simpler shapes and larger parts that do not require the same level of precision.

What is the alternative to high-pressure casting?

An alternative to high-pressure casting is gravity casting. Gravity casting involves pouring molten metal into a mold without the use of high pressure. While it is less suitable for highly detailed and precision parts, gravity casting is well-suited for larger and simpler shapes. Other alternatives include low-pressure die casting and sand casting, each with its own set of advantages and limitations depending on the specific requirements of the casting project.

Custom High Pressure Die Casting Services

Welcome to TEAM MFG's dedicated space on High Pressure Die Casting—a realm where innovation meets precision, and possibilities are forged under immense pressure.

Dive into the heart of manufacturing excellence, explore the nuanced landscape of its Advantages And Disadvantages, and witness the diverse Applications that make this process an indispensable force in the industry.

We specialize in custom high pressure die casting services for industries demanding precision, durability, and cost-efficiency. As a trusted die casting manufacturer in China, we offer aluminum and zinc die cast parts with tight tolerances, ideal for both low-volume and high-volume production.

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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 simple/complex shapes and tight tolerances by injecting molten metal into a steel mold (die) under high pressure.

Here are the key features of high pressure die casting:

High Pressure: Molten metal (typically aluminum, zinc, or magnesium) is forced into the die at pressures ranging from 1,000 to 20,000 psi.
Steel Dies: The process uses hardened steel molds that are reusable for thousands of cycles.
Fast Cycle Time: Each casting cycle takes only seconds to minutes, making it ideal for mass production.

How Does High Pressure Die Casting Work？

High pressure die casting process step by step

Prepare the Mold

The first step in High Pressure Die Casting Process is the preparation of the mold. The mold, also known as the die, is a carefully designed cavity that determines the final shape of the product. It's typically made of two parts, the cover die, and the ejector die, which come together to form the desired shape. The mold is preheated to a specific temperature to ensure proper metal flow and solidification during the casting process.

Inject the Material

Once the high pressure die casting tooling is ready, the next step is to pull up the mold onto high pressure die casting machine, and inject the molten metal into the tooling. This is a crucial stage and can be executed through two main methods: Hot Chamber Injection and Cold Chamber Injection.

Hot Chamber Die Casting

Hot Chamber Injection is suitable for metals with low melting points, such as zinc, tin, and lead. In this method, the injection system is immersed in a molten metal bath. The plunger, which is part of the injection system, is used to push the molten metal into the die cavity under high pressure. This process ensures a continuous and fast casting cycle, making it efficient for mass production.

Cold Chamber High Pressure Die Casting

For metals with higher melting points, like aluminum and copper, Cold Chamber Injection is employed. In this method, the molten metal is poured into a separate chamber, and a plunger is used to transfer the metal into the die cavity. The advantage of this approach is that it prevents the contact between the molten metal and the injection system, reducing wear and prolonging the life of the components.

Part Casting

Once the molten metal has solidified inside the mold and taken the shape of the cavity, the next step is to remove the high pressure die casting parts from the mold. The mold is opened, and the ejector pins push the casting out. This step requires precision high pressure die casting process parameters for casting, and care to avoid any damage to the newly formed part.

Trim the Excess Material

After the part is removed from the mold, it often contains excess material, known as flash, which needs to be trimmed off. Flash occurs at the parting line of the mold, where the two halves meet. Trimming is essential for achieving the final desired shape and ensuring that the part meets the required specifications. We can tells the high pressure die casting defects such as porosities after trimming.

Professional Die Casting Manufacturer China - TEAM MFG

TEAM MFG offers custom high pressure die casting services tailored to meet the needs of industries requiring complex, low to high-volume, and dimensionally accurate metal components. Our capabities includes:

Tooling & Mold Making:

In-house die design & tooling with fast lead time → Optimized for cycle time, part longevity, and performance

Materials:

Aluminum (ADC12, A380, AlSi9Cu3), Zinc (Zamak 3, Zamak 5), and Magnesium alloys → Excellent thermal conductivity, corrosion resistance, and strength-to-weight ratio

Machine Tonnage Range:

From 160 tons to 1,600 tons → Supports small precision parts to large structural castings.

Production Volumes:

Low to high-volume production (100 – 1,000,000+ parts/year)

Part Size & Complexity:

Tight tolerance, thin walls, fine details
→ Ideal for automotive, electronics, aerospace, and industrial applications

Secondary Operations:

CNC Machining (3, 4, 5-axis), Drilling, tapping, and trimming
Surface finishing: Powder coating, anodizing, plating, painting
Assembly and packaging

Quality Control:

ISO 9001:2015 certified, CMM Inspection, X-ray analysis, leak testing, porosity testing

High Pressure Die Casting Capabilities at TEAM MFG

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.

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High Pressure Die Casting Advantages And Disadvantages

Advantages of High Pressure Die Casting

Higher Production Rates:

Team-MFG's High Pressure Die Casting ensures swift and efficient metal part production, meeting high-volume demands with ease.

Good Quality Parts Manufactured:

Consistent precision and tight tolerances make Team-MFG's High Pressure Die Casting a reliable choice, producing superior parts that exceed industry standards.

Ability To Create Thin Walls:

Team-MFG's High Pressure Die Casting offers versatility by crafting intricate designs with thin walls, making it ideal for industries requiring lightweight structures.

Achieve Complex Design:

Team-MFG's High Pressure Die Casting is the solution for intricate designs, allowing designers to innovate and create sophisticated components.

Durable Tools:

Durable molds in Team-MFG's High Pressure Die Casting contribute to cost-effectiveness and reliability in high-volume production runs.

Disadvantages

Requires Complex and Expensive Equipment:
High Pressure Die Casting offers efficiency but demands sophisticated and costly machinery.
Comparatively High Startup and Operation Costs:
While ensuring high-quality production, High Pressure Die Casting involves relatively higher startup and operational expenses.
Less Suited to Limited Production Runs or Individual Casting:
High Pressure Die Casting excels in medium to high-volume production scenarios but may not be the most cost-effective choice for limited runs or individual casting needs.

Why Us For Pressure Die Casting

Aluminium high pressure die casting manufacturer and iso 14001 / Aluminium high pressure die casting manufacturer and itaf 16949

Professional engineering supports and analysis

Low volume manufacturing is acceptable

High efficiency and fast delivery

Stable quality under ISO quality control system

Multiple materials and methods to cut down investments

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.

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!

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.

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

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.

FAQs on High Pressure Die Casting by Team MFG

Why is it called die casting?

Die casting is named so because it involves the use of a metal mold, known as a die, into which molten metal is injected under high pressure. The term "die" refers to the mold or tool that shapes the metal into the desired form during the casting process.
Is high-pressure die casting for plastics?

No, highpressure die casting is primarily used for metals, not plastics. In this process, molten metal is injected into a die under high pressure to produce complex and detailed metal parts with high accuracy and surface finish. Plastics, on the other hand, are commonly processed using injection molding techniques.
What is the difference between low-pressure and high-pressure die casting?

The main difference lies in the pressure used to inject molten metal into the die. In low-pressure die casting, the metal is typically forced into the mold at a lower pressure, allowing for the production of larger and more massive parts. High-pressure die casting, as the name suggests, involves injecting molten metal at significantly higher pressures, resulting in the production of smaller and more intricate parts with finer details.
What is the difference between high-pressure casting and gravity casting?

The key distinction between high-pressure casting and gravity casting lies in the method of metal injection. High-pressure casting involves injecting molten metal into the die under substantial pressure, enabling the production of detailed and high-precision parts. In gravity casting, on the other hand, the molten metal is poured into the mold using the force of gravity, making it a more suitable method for simpler shapes and larger parts that do not require the same level of precision.
What is the alternative to high-pressure casting?

An alternative to high-pressure casting is gravity casting. Gravity casting involves pouring molten metal into a mold without the use of high pressure. While it is less suitable for highly detailed and precision parts, gravity casting is well-suited for larger and simpler shapes. Other alternatives include low-pressure die casting and sand casting, each with its own set of advantages and limitations depending on the specific requirements of the casting project.

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TEAM MFG is a rapid manufacturing company who specializes in ODM and OEM starts in 2015.

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Custom High Pressure Die Casting Services

What is High Pressure Die Casting

How Does High Pressure Die Casting Work？

Prepare the Mold

Inject the Material

Hot Chamber Die Casting

Cold Chamber High Pressure Die Casting

Part Casting

Trim the Excess Material

Professional Die Casting Manufacturer China - TEAM MFG

 Tooling & Mold Making:

 Materials:

 Machine Tonnage Range:

 Production Volumes:

 Part Size & Complexity:

 Secondary Operations:

 Quality Control:

High Pressure Die Casting Capabilities at TEAM MFG

High Pressure Aluminum Die Casting

High Pressure Zinc Die Casting

Mold Tooling Steel

Die Casting Aluminum

Post Machining

3-axis, 4-axis, 5-axis CNC Post-Machining

Surface Finishes For Your Casting Parts

High Pressure Die Casting Advantages And Disadvantages

Advantages of High Pressure Die Casting

 Higher Production Rates:

 Good Quality Parts Manufactured:

 Ability To Create Thin Walls:

 Achieve Complex Design:

 Durable Tools:

Disadvantages

Why Us For Pressure Die Casting

High Pressure Die Casting Process Applicatoins

Automotive

Aerospace

Medical

Looking for High Pressure Die Casting Companies

Videos of Our Daily Works

High Pressure Die Casting Case Studies

High Pressure Die Casting vs Low Pressure Die Casting

FAQs on High Pressure Die Casting by Team MFG

Why is it called die casting?

Is high-pressure die casting for plastics?

What is the difference between low-pressure and high-pressure die casting?

What is the difference between high-pressure casting and gravity casting?

What is the alternative to high-pressure casting?

Rapid Manufacturing Latest Blogs

Detailed Guide of Bronze Machining 2025: From Tool Selection To Perfect Surface Finish

ABS Plastic: A Detailed Guide To Know Its Uses

Detailed Insert Molding Guides 2025: From CAD Design to Final Quality Control

Quick Link

Tel

Phone

Email

Tooling & Mold Making:

Materials:

Machine Tonnage Range:

Production Volumes:

Part Size & Complexity:

Secondary Operations:

Quality Control:

Higher Production Rates:

Good Quality Parts Manufactured:

Ability To Create Thin Walls:

Achieve Complex Design:

Durable Tools: