Die Casting
High-pressure die casting for aluminum and zinc alloy parts. Ideal for high-volume production of complex thin-walled components with excellent surface finish.
About Die Casting
Die casting produces high-volume metal parts by injecting molten aluminum or zinc alloy into hardened steel dies under high pressure (1,000-25,000 psi). The process creates complex thin-walled parts with excellent surface finish and dimensional accuracy in cycle times of 30-90 seconds.
FabRapid operates high-pressure die casting machines from 250 to 1,600 tons clamping force, producing parts from 10 grams to 15 kilograms. We specialize in aluminum alloys (A380, A360, ADC12) and zinc alloys (Zamak 3, Zamak 5) for automotive, electronics, lighting, and industrial applications.
Die casting is the most cost-effective method for high-volume production of complex metal housings, brackets, and structural components. Tooling investment is higher than machining but per-unit cost drops dramatically at volumes above 5,000 units.
Key Capabilities
Complex Thin-Wall Geometries
Cast aluminum walls as thin as 0.8 mm and zinc walls as thin as 0.4 mm with complex internal features, ribs, and bosses in a single operation.
High-Volume Production
Cycle times of 30-90 seconds enable production of thousands of parts per day. Die life of 100,000+ shots for aluminum and 1M+ for zinc.
Excellent Surface Finish
As-cast surfaces achieve Ra 1.6-3.2 µm — smooth enough for painting or plating without extensive preparation.
Secondary CNC Machining
Critical surfaces, bores, and threads are CNC machined after casting to achieve tight tolerances not possible in the as-cast condition.
Technical Specifications
How Die Casting Works
Part & Die Design
Our engineers review your part for castability — draft angles, wall uniformity, gate location, and ejector pin placement. Die flow simulation optimizes fill patterns.
Die Fabrication
Precision-machined H13 steel dies with hardened cavity inserts, cooling channels, and ejection systems. Typical lead time: 6-8 weeks.
Sample Casting & Approval
Initial sample runs establish optimal casting parameters. Dimensional reports and material certifications confirm quality before production release.
Production & Secondary Operations
High-speed production casting with automated extraction and trimming. Secondary CNC machining, tapping, and surface finishing complete the parts.
Our Die Casting Services
Explore our specialized die casting capabilities for your specific application.
Aluminum Die Casting
Aluminum die casting for lightweight, strong, and corrosion-resistant parts. Ideal for automotive housings, heatsinks, and structural brackets.
Zinc Die Casting
Zinc die casting for high-detail, thin-walled parts with excellent dimensional stability. Ideal for connectors, housings, and decorative hardware.
Die Casting FAQ
Die casting becomes more cost-effective than CNC machining at volumes typically above 5,000-10,000 units. The high tooling cost ($15,000-80,000) is offset by low per-unit casting cost. Die casting also enables thin-wall geometries and complex shapes that would be expensive to machine.
Aluminum die castings are lighter with better corrosion resistance and thermal conductivity. Zinc die castings offer tighter tolerances, thinner walls (0.4 mm vs 0.8 mm), longer die life (1M+ vs 100K shots), and better detail reproduction. Zinc is preferred for small, detailed parts; aluminum for larger structural components.
Ready to Start Your Die Casting Project?
Upload your CAD file and get an instant quote. Most parts ship in 3-5 business days.