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Benefits of Die Casting
Die Casting Standard Tolerances
Die casting tolerances rely on alloy type and part geometry. High‑pressure die casting delivers consistent dimensional accuracy; secondary machining can achieve tighter tolerances for precision‑critical casting components.
Part Size Range |
Dimensional Tolerance |
Wall Thickness Tolerance |
Surface Roughness (Ra) |
|---|---|---|---|
| ≤ 50 mm | ± 0.10 mm – ± 0.20 mm | ± 0.15 mm | 1.6 – 3.2 µm |
| 50 mm – 100 mm | ± 0.15 mm – ± 0.30 mm | ± 0.20 mm | 1.6 – 3.2 µm |
| Over 200 mm | ± 0.30 mm – ± 0.50 mm | ± 0.2 mm / 100 mm | 1.6 – 6.3 µm |
Die Casting Service Capabilities
Our die casting service handles aluminum and zinc alloy components. We support complex‑geometry part production, from prototype validation to high‑volume mass manufacturing with post‑processing options available.
Lead Time for Die Casting Service
Die casting lead time includes mold fabrication and production runs. Standard orders take 15‑25 working days, while urgent batches are available once tooling is completed for mass‑production components.
Order Type |
Project Features |
Standard Lead Time |
|---|---|---|
| Standard Order | Existing mold, medium to high volume | 10–15 business days |
| New Mold Project | Custom mold design & manufacturing | 25–35 business days |
| Express Order | Existing mold, urgent small batches | 5–7 business days |
Dai Casting Materials
We work with a wide range of certified, traceable materials selected to match your performance, regulatory, and application requirements. Our engineers provide DFM guidance to optimize your plastic and metal parts design for manufacturing. Contact us or upload a CAD file for material options, instant quotes, and custom production solutions.
Aluminum A380
The most widely used die casting alloy. Offers an excellent balance of fluidity, mechanical strength, and corrosion resistance at a competitive cost. The industry standard for automotive parts, electronic housings, and general-purpose components.
Aluminum A383
A high-fluidity aluminum alloy specifically formulated for complex, thin-walled die castings. Offers excellent castability and pressure tightness. Ideal for electronic enclosures, connector housings, and intricate geometric parts.
Aluminum A413
A silicon-rich aluminum alloy with exceptional castability, pressure tightness, and corrosion resistance. Excellent for parts requiring leak-free performance. Used for hydraulic manifolds, pump housings, and fluid-handling components.
Aluminum B390
A wear-resistant aluminum alloy with high silicon content, designed for components subject to friction and thermal load. Excellent hardness and hot strength. Used for engine blocks, cylinder heads, compressor parts, and brake components.
Zinc Zamak 3
The most common zinc die casting alloy, known for excellent dimensional stability, castability, and surface finish. Low melting point reduces tool wear and energy costs. Used for hardware, decorative parts, locks, and electronic components.
Zinc Zamak 5
A higher-strength zinc alloy with improved hardness and creep resistance compared to Zamak 3. Slightly reduced ductility in exchange for better mechanical performance. Used for gears, automotive components, and load-bearing hardware.
Magnesium AZ91D
The most popular magnesium die casting alloy, offering an exceptional strength-to-weight ratio — roughly 35% lighter than aluminum. Good castability and corrosion resistance. Used for automotive structural parts, laptop housings, and power tool bodies.
Magnesium AM60B
A high-ductility magnesium alloy with excellent impact resistance and energy absorption. Lower yield strength than AZ91D but far superior elongation. Ideal for automotive safety components, seat frames, and structural brackets requiring toughness.
Brass / Copper
A strong, wear-resistant engineering plastic with low friction and good mechanical strength. Absorbs moisture, which increases toughness. Widely used for gears, bearings, bushings, fasteners, and high-wear mechanical components.
Dai Casting Surface Finishes
Die cast parts accept powder coating, anodizing, plating and shot blasting. These finishes remove casting defects, boost corrosion resistance and fulfill both functional protection and decorative appearance demands.
Grinding & Lapping
Passivation process
Abrasive machining process using grinding wheels or lapping compounds to remove material and produce extremely flat, smooth surfaces with tight dimensional tolerances (Ra 0.1–0.8 µm). Surface grinding produces flat parts, cylindrical grinding produces round shafts, and lapping achieves ultra-flat mirror-like surfaces. Essential for precision gauges, bearing surfaces, die sets, and any component requiring extreme flatness and surface accuracy.
Polishing & Buffing
Passivation process
Mirror polishing is a finishing process that gives metal a smooth, shiny, mirror-like surface. It works by using abrasive compounds starting coarse and moving to progressively finer grades along with soft cloth or felt buffing wheels to remove scratches, tool marks, and other surface flaws. This process achieves the highest possible shine, with a surface roughness of about Ra 0.025–0.1 µm (extremely smooth). It’s commonly used for decorative stainless steel panels, medical instruments, automotive trim, jewelry, and premium consumer products that need a flawless, reflective finish.
Bead / Abrasive Blasting
Passivation process
High-pressure projection of glass beads, aluminum oxide, or other abrasive media onto a surface to create a uniform matte satin, non-reflective finish. Hides scratches, weld seams, and surface inconsistencies, produces a consistent fine grain texture (Ra 0.8–3.2 µm). Used for aluminum and stainless steel brackets, enclosures, medical devices, and industrial components where a clean, uniform, non-glare matte appearance is desired.
Brushing / Grain Finishing
Passivation process
Mechanical brushing with abrasive belts or nylon brushes creates a uniform directional linear grain pattern across the surface. Hides scratches and surface imperfections, produces a consistent semi-matte appearance (Ra 0.4–1.6 µm). The most popular decorative finish for stainless steel and aluminum are used for kitchen equipment, architectural panels, appliance housings, and consumer product enclosures requiring a refined directional texture.
Deburring & Edge Breaking
Passivation process
Post-machining process that removes burrs, sharp edges, and residual material from cut or machined surfaces, producing clean, smooth, safe-to-handle edges. Methods include hand deburring, tumbling, vibratory finishing, and thermal deburring. Standard for all handled parts, assemblies, and components where sharp edges would be a safety concern or interfere with assembly that’s essential for quality and safety in every manufacturing process.
Anodized (Aluminum)
Passivation process
Electrochemical process that creates a hard, corrosion-resistant, dyeable aluminum oxide layer on aluminum surfaces. Available in any color (black, blue, red, clear), provides wear protection and improved corrosion resistance. Type II (standard) for general use, Type III (hard coat) for high-wear applications. Widely used for aluminum enclosures, electronic housings, aerospace components, and architectural panels requiring a durable, colored, corrosion-resistant finish.
Electropolishing
Passivation process
Electrochemical process that removes a thin layer of metal from the surface by anodic dissolution in an electrolyte bath, producing an ultra-smooth, bright, highly reflective finish (Ra 0.05–0.4 µm). Removes micro-burrs, improves corrosion resistance, and creates a clean, sterile surface. Widely used for stainless steel medical instruments, food processing equipment, pharmaceutical components, and any application requiring ultra-clean, corrosion-resistant surfaces.
Plating (Chrome / Nickel / Gold)
Passivation process
Electrochemical deposition of a thin metal layer (chrome, nickel, gold, silver, zinc, tin) onto a substrate surface to improve appearance, corrosion resistance, wear resistance, or electrical conductivity. Chrome plating provides a bright, hard, reflective finish; nickel plating provides corrosion protection and a smooth base; gold plating provides excellent conductivity and tarnish resistance. Used for automotive trim, electrical contacts, fasteners, and decorative hardware.
Plating (Chrome, Nickel, Gold)
Passivation process
Powder coating: electrostatic dry powder paint followed by thermal curing creates a durable, uniform matte or satin finish in any RAL color, with excellent corrosion and scratch resistance. Wet painting: conventional liquid paint (acrylic, epoxy, polyurethane) applied over a primed surface, available in any custom color and gloss level. Both provide protective and decorative finishes for enclosures, equipment housings, automotive parts, and outdoor industrial components.
Passivation & Conversion Coating
Passivation process
Passivation: chemical treatment (citric or nitric acid) removes free iron and contaminants from stainless steel, restoring and enhancing the protective chromium oxide layer for improved corrosion resistance does not change appearance or dimensions. Conversion coating (chromate, phosphate, black oxide): chemical process creates a thin protective layer on metal surfaces, improving paint adhesion and corrosion resistance. Standard post-fabrication treatment for stainless steel, steel, and aluminum components.
