Service Metal Sheet Die Casting
Service Metal Sheet Die Casting
Service Metal Sheet Die Casting

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Custom Die Casting Services

High Quality Die Cast Metal Parts.

Mucision’s Die Casting Service

Die casting is the preferred manufacturing method for producing high volumes of intricate metal parts, valued for its adaptability, dependability, and precision. This process often eliminates secondary operations required for metal part fabrication, although post-machining is common to achieve tighter critical tolerances. Die cast parts can be finished similarly to their CNC-machined counterparts.
Like injection molding, die casting involves creating a die or mold tool with one or multiple cavities. Suitable for softer alloys such as aluminum and zinc due to their lower melting temperatures, die casting works by injecting molten metal into the die cavity, which adopts the part’s shape and solidifies before removal. Die casting can be low- or high-pressure, employing a ladle or plunger for metal deposition based on project scope.
Die casting offers repeatable, high-quality production of complex parts with tight tolerances for various industries, including squeeze casting and semi-solid metal casting. Most die casting companies specialize in aluminum or zinc casting, with aluminum constituting about 80% of die cast parts.
Our dedicated project managers and experts manually review and quote each die casting project, ensuring personalized solutions and a seamless manufacturing experience. Explore the process and our capabilities further in the subsequent sections.

① Start A Quote

Submit your files to our Quote system and tailor your project settings. Our team will collaborate with you to ensure your project requirements, lead time, and budget are aligned. Before initiating tooling, we will provide a DFM report for your approval, ensuring a smooth and efficient process.

② Sample Approval

Upon project initiation, we will construct a top-quality die. After tooling completion, we will send part samples, referred to as T1s, for your review and approval to ensure the components meet your specifications.

③ Production Begins

When you are content with the part samples, we proceed with full-scale production and deliver the finished components. Mucision handles supplier management and logistics throughout the process, providing a hassle-free experience. You retain ownership of the tooling, allowing for convenient reordering as needed to meet ongoing demand.

Applications of Die Casting

The adaptability and high production capacity of die casting make it suitable for diverse applications across various industries. Die casting is ideal for small to medium-sized products with intricate features, such as consumer and industrial products, automotive parts, aerospace components, and medical device parts. When high-volume metal parts are required, but are too large for processes like Metal Injection Molding (MIM), die casting is a viable alternative.

Service Metal Sheet Die Casting

Why Choose Mucision for Die Casting?

Boundless Options

Select from an extensive range of material, finish, tolerance, marking, and certification combinations to customize your order.

User Friendly

Enjoy convenient, hassle-free delivery of your parts directly to your doorstep, eliminating sourcing, project management, logistics, and shipping concerns.

Enriched Network

We are ISO 9001:2015, ISO 13485, IATF 16949:2016, and AS9100D certified.

Service Metal Sheet Die Casting

Die Casting Types Available at Mucision

The hot chamber die casting process, also known as gooseneck casting, is the most widely used die casting technique. Ideal for lower melting point alloys like zinc, magnesium, and lead, this process involves filling a holding pot with metal and heating it using an integrated or attached furnace. The hot chamber system features a gooseneck that forms a holding chamber within the pot and connects to the fixed half of the die’s injection cavity. A plunger above the chamber loads it with molten metal from the holding pot, then lowers to force the metal up the gooseneck into the die cavity. The mold remains closed under pressure during metal cooling and solidification. Once sufficiently cooled, the dies open, and ejector pins release the casted piece.

In the cold chamber die casting process, the chamber stays at room temperature without a molten metal holding pot. Metal is melted in a separate furnace and manually poured into the shot chamber via a pouring hole using a ladle. The mold directly connects to the shot chamber, and instead of a plunger system, a ram forces molten metal into the mold and maintains high pressure during solidification. Cold chamber die casting is ideal for materials with higher melting temperatures, such as aluminum.

Aluminum alloys are the most popular choice for die cast parts, providing aluminum die casting suppliers with complete recyclability and ease of use. Due to their higher melting point, aluminum die casting often requires the cold chamber casting process. Cast aluminum parts are favored by engineers for their excellent strength to weight ratios, dimensional stability, and versatile finishing options. Other common characteristics of cast aluminum alloys include:
  • High operating temperature resistance
  • Corrosion resistance
  • Good stiffness
  • High thermal and electrical conductivity
Engineers and designers can select from various alloys for their aluminum casting parts. Xometry offers several popular aluminum die casting alloys:
  • A360.0
  • A380.0
  • A383.0 (ADC12)
  • A413.0

Zinc is the most effortless material to cast in die casting processes and is commonly used in hot chamber processes. Its exceptional casting fluidity and lower melting point make it an ideal choice for creating intricate parts with thinner walls and fine details while maintaining tight tolerances. The rapid cooling and solidification of die casting zinc alloys result in the fastest production rates among die casting materials. Zinc’s well-rounded performance comes from its balanced mechanical and physical properties:
  • Impact strength
  • High hardness
  • Great stability
  • High-quality surface finish and easy plating
  • Low melting point
These characteristics make zinc an optimal choice for various die casting applications.

Available Die Casting Finishes

Zinc and aluminum zinc parts can maintain adequate corrosion resistance without additional treatment when left as-cast. However, aluminum parts require coating to achieve corrosion resistance. Cast parts usually exhibit rough marks at gate locations due to separation from the casting sprue, and ejector pins may leave visible marks. The typical surface finish for as-cast zinc alloys ranges between 16-64 microinch Ra.

The part surface is media blasted, typically using glass bead, to produce a smooth, matte appearance.

Type II creates a corrosion-resistant finish. Parts can be anodized in different colors—clear, black, red, and gold are most common—and is usually associated with aluminum. Type III is thicker and creates a wear-resistant layer in addition to the corrosion resistance seen with Type II.

This is a process where powdered paint is sprayed onto a part which is then baked in an oven. This creates a strong, wear- and corrosion-resistant layer that is more durable than standard painting methods. A wide variety of colors are available to create the desired aesthetic.

All die cast parts can be wet painted in a wide variety of paint formulations and colors.

Suppliers can apply a chromate conversion coat to protect aluminum from corrosion and improve the adhesion of paints and primers. Chemical film conversion coatings are electrically conductive.

Die cast parts can be plated with electroless nickel, nickel, brass, tin, chrome, chromate, Teflon, silver and gold.

Die cast materials are subjected to vibratory media tumbling to remove sharp edged and smooth surfaces.

Don’t see the finish you need? Submit an RFQ and our partner shops will look into a finishing process for you.

 

Service Metal Sheet Die Casting

Ready to get started on your quote?

Mucision Die Casting Capabilities

Description
Minimum Part Weight 0.017 kg
Maximum Part Weight 12 kg
Minimum Part Size ∅17 mm × 4 mm
Maximum Part Size 300 mm × 650 mm
Minimum Wall Thickness 0.8 mm
Maximum Wall Thickness 12.7 mm
Quality Control ISO 9001 Certified
Minimum Possible Batch 1000 pcs

 

 

Advantages

Advantages of Die Casting

Complex Geometry
Die casting can create durable and dimensionally stable custom parts with intricate geometry and thin walls.
Strength
Metal die castings are typically more robust than plastic injection-molded parts, offering higher resistance to high temperatures. Materials like aluminum provide exceptional strength-to-weight ratios.
Precision
Die casting achieves typical tolerances ranging from +/-0.003″ to 0.005″ per inch but can reach as tight as +/- 0.001″ based on specifications, part geometry, and material.
Custom Finishes
Metal finishers can produce cast parts with smooth or textured surfaces, paints, and plating finishes that protect against corrosion and enhance cosmetic appearance.

Disadvantages

Disadvantages of Die Casting

Tooling Cost
Although die cast parts have a relatively low per-piece cost, the initial investment in tooling dies and maintenance can be significant.
Not Suitable for Low Quantities
Due to high upfront tooling costs, die casting is not cost-effective for low-volume runs. It is advisable to consider die casting only for quantities above 1000.
Lead Times
The die casting process requires several steps before production, such as addressing DFM concerns, tool design, tool manufacturing, and sample creation. These initial checks and validations make die casting comparatively slower to ramp up compared to other manufacturing processes.