What is Pressure Die Casting
Pressure die casting is a metal low-volume and mass-production technique. Pressure die casting service involves injecting molten metal into a mold cavity or steel die under high pressure to produce strong, functional, and trustworthy parts that match design specifications. The process is similar to injection molding and is a guaranteed method of making average to substantial volumes of metal parts. The high pressure involved in the process is essential to ensure that all the mold details are arrested on the casted parts. Premium Parts employs state-of-the-art machines and high-quality pressure casting dies to produce parts with excellent surface finish, tight tolerances, and inch-perfect dimensional precision. With varied and extensive experience in die casting, our process is dynamic, practical, and cost-effective. Choose from zinc, aluminum, magnesium to accommodate your material, end-use, and volume needs.
Our Pressure Die Casting Processes
At Premium Parts, we run several die casting processes. Our pressure die casting operations may be summarized as hot-chamber or cold-chamber die casting. The hot-chamber die casting process is suitable for casting metal alloys with low melting points and high fluidity. The cold-chamber process is reserved for metals with higher melting temperatures. Cold-chamber processes are frequently used with aluminum, magnesium, and brass, while zinc, magnesium, copper are all cast in hot-chamber processes.
Our pressure die casting process consists of 6 steps. Die-casted parts are manufactured in steel molds similar to those used in injection molding under high pressure and cooled to set into the shape of the casting. Our Premium die casting manufacturing process can be summarized as follows:
Here, the dies are cleaned and lubricated. The die halves are then closed and clamped under high pressure.
During the injection phase, the molten metal is injected and forced into the clamped die under extremely high pressure. The molten metal is kept in the die until it solidifies.
The molten metal, now in the die, is cooled. This process is essential to allow the solidification of the metal. The cooled metal fully forms the part and takes the shape of the casting.
Once the metal has cooled, the ejection process begins. Here, the die halves are unclamped, and the solidified part is pushed out of the die.
This process is a pre-finishing process that ensures removing excess metals in the sprue and runner along with any splash or metal debris. These extra materials are removed from the final die-casted product to ensure cleanliness, dimensional, and physical accuracy.
6. Finishing services (Optional)
After completing the die-casting process, we offer high-quality finishing services ranging from polishing, plating, painting, sandblasting, and powder coating.
Why You Should Use Pressure Die Casting
• Cost per part
Die casting is the most economical method of producing large volumes of metal parts with high quality. Die casting will usually have a lower cost-per-part than other metal production techniques.
• Complex features
Die casting can achieve complex parts and incorporate certain features into the mold design to reduce the need for assembly and joining.
• Dimensional accuracy
Die casted parts have excellent dimensional accuracy and stability. Because of the high pressure involved, parts are made to replicate the mold tool’s exact specifications.
• Finishing options
The surface finish and cosmetic appearance of castings can range from smooth to textured as required. Castings can be anodized, painted, or polished to give the desired aesthetics.
Once the tooling design is concluded, and the mold tool is produced, the die casting cycle time itself is very fast. The average die casting cycle spans between 3 to 60 seconds, making it one of the quickest production techniques.
• Tool life
Because die casting is often used for mass production runs, the mold tooling is usually made from hardened engineering-grade steel. Die casting tools can make up to tens of thousands of parts before wear and tear begin. This makes it an excellent investment.
Die Casting Applications
• Precision parts
Die casting is used for making precision parts that have critical requirements around weight, dimensions, thin walls, tight tolerances, and even cosmetic finish. Normally, the die casting parts would have a post-machining for some critical areas. Die casting is applied in aerospace, automotive, and engineering industries to make parts that must match specifications to ensure functionality and precision in operations.
• Mass production
Die casting can make large parts and even larger volumes of parts. The process is mostly applied to mass production operations where cost can be spread over more volume, and the cost per part is relatively reduced. This is one of the reasons why die casting operations can help improve the profitability of your parts.
Premium Parts pressure die casting operations can be used in any of the following industries:
• Energy and power
• Consumer products
Aluminum has low weight, high strength, and high castability. It has excellent thermal and electrical conductivity and can be finished in an array of ways. Aluminum castings are naturally corrosion-resistant.
Zinc is very ductile with high density. It is widespread, affordable, and has the easiest castability. Zinc is prone to corrosion and must be coated to manage the chances of rusting. Zinc castings boast good impact resistance and surface characteristics.
Magnesium has a very good strength-to-weight ratio. It is also easily machined and well suited to the rigor of high-performance applications.
Copper is used for its electrical conductivity, high strength, and dimensional stability. While the material may be a little pricey, it has excellent wear and tears resistance.
At Premium Parts, our metal castings can be subjected to several finishing solutions to bring the best out of your parts cosmetically and performance-wise. Some of our finishing techniques for pressure die casting include:
• Powder coating
• CNC machining
Premium Die Casting – Why You Should Work With US
Our competitive advantages in each manufacturing solution that we offer are what sets us apart from others. Our pressure die casting solutions have been optimized to produce the best parts that match our clients’ high-performance needs. Here are some of the reasons you should choose Premium Parts pressure die casting solutions:
• Quality and Consistency
Premium Parts uses experience and capacity to bring you the best die-casted parts. We take every step seriously before delivery, and run every production process, from raw material sourcing to finishing, through our quality control systems.
• Cost and Profitability
Premium Parts adds value to our client’s businesses by exploring ways to deliver your parts at a lower cost-per-part to help you drive your profitability and business margins. Premium Parts is one of the most competitive manufacturing businesses in China.
• Shorter lead times
We will optimize our pressure die casting services to help you get to your target audience quicker. Our in-house capacity also helps us make tooling faster, shorten casting cycles, and land products quicker.
• One-stop shop
Premium Parts can handle your entire product development cycles from design to prototypes and the final part. Our one-stop-shop services also cover your product development from raw material screening to casting and finishing solutions that enhance your parts’ appearance and functionality.
Request A Quote
Choose Premium Parts pressure die casting services and accelerate your metal manufacturing orders right away. With our vast experience and machining capabilities, our die casting solutions are your best option for making quality end-use parts with excellent finish and dependable quality.
Die Casting RFQs
1. When can I receive the DFM for my part?
We can offer the DFM free of cost with quote sending.
2. How can you ensure my part can work as specified?
Before running full of the order, we would send our clients 3-5 parts for testing or confirmation. We would only mold all the parts after getting approval from our client. If the initial units are out of expectations, we would keep fixing the tool until parts are accepted by our customers.
3. How long can you store our tooling before the next order?
We can store your tooling for up to 5 years, after your last order.
4. If our tooling was broken before the expected quantity molded, what can you do for us?
Generally, if our tooling was running out of its’ tooling life, we can remake another new mold free of cost.
5. Can I export my tooling?
Yes, but please try to let us know when inquiring.