FAQs

Die casting is a manufacturing process in which molten metal is injected into a steel mould (die) under high pressure to create complex metal parts with excellent dimensional accuracy and surface quality.

Precision die casting refers to a higher standard of die casting, involving enhanced mould design, stricter process control, premium alloys, and post-processing techniques. It is ideal for parts requiring tight tolerances, high structural integrity, and visual consistency across production batches.

Precision die cast components must meet demanding tolerances, such as:

• Dimensional accuracy: ±0.01mm to ±0.05mm
• Flatness: ≤0.1mm (depending on size)
• Coaxiality/perpendicularity: ≤0.05mm
• Surface roughness: Ra1.6–Ra3.2μm
• Sealing integrity: Air/water pressure testing for leak-tight parts (e.g., EV motor housings)

These tolerances make precision die casting suitable for critical applications in electronics, automotive, drones, and medical devices.

Key considerations during the precision die casting process include:

1. Mould design: Optimised gating, venting, and cooling systems to prevent porosity or shrinkage
2. Material selection: High-purity alloys with stable melting behaviour (e.g., ADC12, ZL101, AZ91D)
3. Process control: Accurate management of pressure, injection speed, and temperature
4. Mould temperature management: Stability is essential to avoid deformation and cracks
5. Post-processing: CNC machining, de-burring, and surface treatments (anodising, plating, etc.) ensure product consistency

Precision die casting offers several key advantages over traditional sand casting, especially when it comes to dimensional accuracy, production efficiency, and surface quality.

First, tolerance control is significantly better in precision die casting, with dimensional accuracy reaching ±0.01mm, whereas sand casting typically requires extensive post-machining to meet acceptable tolerances. Secondly, the surface finish of die cast parts is much smoother—typically around Ra 1.6μm—compared to the rougher finish of sand cast components, which usually exceed Ra 6.3μm.

In terms of production, precision die casting supports high-speed, high-volume manufacturing, making it ideal for OEMs looking for scalability and repeatability. Sand casting, by contrast, is slower and less suitable for large batch production.

Tooling life is also a major differentiator. Precision die casting moulds can last for tens of thousands of cycles, while sand casting patterns are generally single-use or low-cycle. Finally, material usage and automation are more efficient in precision die casting, reducing overall production waste and labour dependency.

Due to these advantages, precision die casting is the preferred choice for applications requiring both accuracy and manufacturing efficiency across multiple industries.

• Automotive: Engine covers, EV motor housings, gearbox cases
• Consumer electronics: Phone frames, laptop bases, heat sinks
• Power tools: Gear housings, tool enclosures, connectors
• Smart appliances: Coffee machine panels, fan bases, heating shells
• Energy storage: Battery trays, inverter housings
• Drones and aerospace: Lightweight frames, structural supports
• Common materials used:
• Aluminium alloys: ADC12, A380, ZL101 – lightweight, conductive, corrosion-resistant
• Magnesium alloys: AZ91D, AM60B – ultra-light, shock-absorbent
• Zinc alloys: Zamak 3/5, ZA-8 – highly fluid, great surface finish
• Copper alloys (occasionally) – for high-conductivity or corrosion-prone components