Aluminum Die Casting

The die casting process forms precise metal parts using pressure to completely fill all cavities within a mold. Die casting works with numerous non-ferrous metals, such as aluminum, and magnesium, among others. The die itself is made from a harder metal, such as tool steel, to ensure long-term functionality with minimal production wear. This fabrication method provides an ideal solution for producing complex designs in high volumes.

At DyCast Specialties, we specialize in providing high-quality aluminum die casting services for a wide variety of industries and applications.

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Why Aluminum?

Aluminum sees frequent use in die castings for producing lightweight, intricate designs. At DyCast Specialties, we work with the following aluminum alloys:

  • 380 Aluminum. This popular alloy is both versatile and cost-effective.
  • 383 Aluminum. This alloy offers a greater workability than aluminum 380, especially for filling dies and molds, though the finished product may have lower toughness.
  • 413 Aluminum. The 413 alloy is the most fluid aluminum alloy available, ideal for filling complex molds under pressure without gaps.

Regardless of the specific type of aluminum selected for individual projects, aluminum in general offers various beneficial characteristics:

  • Conductivity. Aluminum conducts electricity and thermal energy well.
  • Dimensional stability. This metal maintains good dimensional stability, even in parts with very thin walls. Aluminum’s stability also makes it an excellent choice for complex parts.
  • Mechanical properties. Aluminum offers a good degree of hardness, shear strength, and tensile strength. These and other mechanical properties make aluminum a good choice for commercial and industrial parts that require reliable long-term performance.
  • Resistance to corrosion. Aluminum resists corrosion and oxidation, making it useful for mitigating the risk of rust in indoor or outdoor applications.
  • Strength. Aluminum is a strong metal with an excellent strength-to-weight ratio, even maintaining its strength at high temperatures.
  • Weight. Aluminum is a lightweight metal, especially compared to steel and other popular manufacturing materials. This is important for designing fuel-efficient vehicles, aerospace parts, handheld consumer goods, construction elements, and other products where lower component weight may improve performance.

Common Applications

A wide variety of industries rely on aluminum for its versatility and compatibility with the die casting process. Some of the most popular applications of aluminum die casting parts include:

  • Appliances. Die casting produces identical and interchangeable parts, which is crucial for mass-manufactured consumer appliances.
  • Automotive. Aluminum automotive parts are strong and lightweight, which enhances fuel efficiency for automobiles and heavy trucks.
  • Electric motors and fluid pump motors. Aluminum has excellent dimensional stability, even at the high temperatures found in motor and pump operation.
  • Hand tools. Aluminum tools are lightweight, strong, and easy to handle.
  • Hardware (fasteners). Aluminum fasteners withstand corrosion and environmental wear for a long-lasting hold.
  • LED lighting. Aluminum components conduct electricity well, contributing to the efficiency to LED lighting.
  • Medical/healthcare. Medical devices need to be strong, lightweight, and rigid for easy use by medical professionals.
  • Military. Aluminum is a strong, cost-effective material choice for vehicle components, electronics, and structural components.
  • Recreational (interior/exterior parts). Aluminum fasteners, grommets, and other hardware are strong, rigid, and resistant to environmental damage.
  • Retail scanning. Die casting produces housings and hardware components used in retail scanning equipment.
  • Robotic automation. Industrial systems require strong, high-quality aluminum components that can integrate with other hardware.
  • Security. Die casting aluminum produces high-precision components for smart locks, security cameras, and other security devices.
  • Video conferencing. Precision video conferencing system parts and housings are often produced using die casting.

Quality Aluminum Die Casts from DyCast Specialties

At DyCast Specialties, we provide complete high pressure aluminum die casting services. We manage the entire process, from the initial design through machining, finishing, and shipping. Our facility includes an in-house machining center with tolerance capabilities within +/- 0.00025 of an inch. Our additional processes include coatings, annealing, testing, inspecting, and assembly.

Contact us today to see how our quality die cast aluminum components can support your project.

At DyCast Specialties, we provide complete high pressure aluminum die casting services.

Request a Quote Today

Specifications

Die Cast Alloys

Aluminum Alloys: 380, 383, 413

Die Cast Cells

Aluminum – Hiqh Pressure:

(1) – 725 ton Die Casting Machine
(2) – 600 ton Die Casting Machine
(3) – 600LB/Hour – 4800LB Capacity Furnace

Tolerance

+/- 0.0025

Maximum Weight

10 Pound

Tooling Construction

All molds are constructed from Premium H-13 tool steel and are heat treated to 46-48 R/C.
Tooling, molds & dies are produced through Dycast Specialties’ in-house tooling department, out-sourced tooling vendors, and overseas vendors.

Mold Longevity

Up to 100,000 shots

Tooling concept

10″ x 12″ Standard DME Unit Dies
12″ x 15″ HD DME Unit Dies
12″ x 15″ Standard DME Unit Dies

15″ x 18″ HD DME Unit Dies
8″ x 8″ House Inserts
Standard Cavity Retainer Sets

Equipment List

Trim Press Cells :

  • 3-6 ton Trim Press
  • 1-20 ton Trim Press
  • 1-35 ton Trim Press
  • 10 – 8 ton Trim Press
  • 2-10 ton Trim Press
CNC Machining

Machining Centers :

  • 3 – CNC Vertical milling center with pallet changer
  • 3 – CNC Vertical milling machine

Machine fixtures and CNC centers capable of producing tolerances of +/- . 00025

Deburring

Tumble Deburring:

  • Commercial type hardware finish.
  • Utilizes a part on part barrel action to polish the casting surface, remove flash, and reduce sharp edges.
Finishing

Vibratory Finishing:

  • Premium visual cosmetics
  • Utilizes plastic and ceramic medias to polish the casting surface and reduce sharp edges.
Additional Process

Annealing
Assembly
Black Zinc Chromate
Bright Zinc Chromate
Chromate Conversion
Clear Anodizing
E-Coating

Liquid Paint
Pad Printing
Powder Coat Paint
Shot Bead Blasting
X-Ray
Yellow Zinc Chromate