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Die Castings Manufacturers and Companies

IQS Directory provides a comprehensive list of die casting manufacturers and suppliers. Use our website to review and source top die casting manufacturers with roll over ads and detailed product descriptions. Find die casting companies that can design, engineer, and manufacture die castings to your companies specifications. Then contact the die casting companies through our quick and easy request for quote form. Website links, company profile, locations, phone, product videos and product information is provided for each company. Access customer reviews and keep up to date with product new articles. Whether you are looking for manufacturers of alloy die casting, automotive casting, die casting products, or customized die castings of every type, this is the resource for you.

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Precision die castings plus a multitude of related services, including engineering, designing, machining, finishing and assembly, occur at A and B Die Casting. Specializing in low to medium volume solutions, we also offer competitive prices. As a manufacturer we have served the architectural lighting, computer, medical hardware and telecommunications industries.
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With over forty-five years experience, Crown Die Casting Corporation specializes in die castings, as well as CNC machining, product design and metal finishing. We provide customers with in house tooling and are registered users of SolidWorks and GibbsCAM. For more information on the extensive product line and list of services that we offer, please visit our website or give us a call!
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Here at MES, Inc. we are a full-service global manufacturing and supply chain. We offer a number of different types of die castings including aluminum die casting, zinc die casting, investment die casting and much more. It is our mission to exceed your expectations. We always keep your production goals in mind which is why we will quickly deliver all of your products.
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Precision Die Casting since 1950. Aluminum die casting and zinc die casting for aerospace, electronic, commercial industries. Turnkey operations from design or your blue print to assembly. Manufacturing services: 3D CAD, mold building, CNC milling and turning, fine finishes, assembly and JIT shipments.
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Modern Aluminum Castings offers customers full-service die castings and related capabilities from design to delivery. We work with a large variety of metal options, making us your one-stop source. For your complete finishing needs we also offer heat treatments, coatings, machining and surface treatments such as vibratory finishes and shot blasting services.
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Our die casting is ideal for those project requiring complex shapes or unique requirements. Our company offers a number of benefits including multiple finishing techniques, high speed production and simplified assembly. Here at Littler Diecast Corporation we utilize an in-house tool shop which allows us to efficiently create special fixtures while eliminating downtime for repairs. Contact us today to learn more information!
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Gibbs delivers consistent quality die casting services to countries worldwide. As leaders in aluminum and magnesium die cast components, you can count on any of our manufacturing facilities. Whether you are in the automotive business or not, our die casting, machining, die building & design services can match your needs. Gibbs products and services will prove themselves to be the "best in class."
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Die Castings

Die casting is a metal forming process in which molten metal is forced into mold cavities under high pressure and then cooled in order to form solid metal parts. Facilities where die castings are made are referred to as foundries. Die cast products are typically made from non-ferrous metal castings such as zinc, aluminum, copper, magnesium, lead, tin, bronze and some alloys; alloy tool steels may be formed through die casting as well, although the preferred fabrication method for steel parts is forging.

For many years, die castings have presented a cost-effective and highly versatile alternative to other metal shaping methods such as forging and hand tooling. Die casting designs are capable of reaching much closer tolerances and far more complex shapes than forgings or stamped metals while requiring minimal secondary tooling and processing. Die casters can manufacture large quantities of aluminum die castings, zinc die castings and other metal castings with exceptional detail, surface quality and dimensional consistency at relatively low cost. Die castings are manufactured by hot chamber or cold chamber die casting, under carefully controlled pressures. The demand for die castings, particularly automotive castings and other castings used in industrial products, is very high throughout the world.

Many manufacturing industries use die cast parts both in their products and equipment. Since the advent of cost-effective plastic formation processes like vacuum forming and injection molding, the prominence of die cast metal shapes has diminished somewhat. For example, store cash register housings used to be made almost exclusively of die cast metal. Today, almost all cash registers are made of molded plastic. Despite this shift, the number of industrial, commercial and consumer utilities that are products of die casting is too large to be accurately counted. Parts that require the strength of metal still use whole die cast parts, such as gumball machine bases, sink faucets, gas pump handles and a wide range of other metal parts. Computer and electronics industries use high tolerance magnesium die castings as housings and interior EMI enclosures as well as miniature zinc die cast parts for various electronic equipment applications. In the automotive industry, almost every engine block is a die cast product. Die cast aluminum valve covers are also very commonly applied in automobile engines. Cast zinc products are also widely used as door and cabinetry handles.

Every die cast metal part is formed in a die. Dies are also sometimes called molds, and every mold is specially designed for shaping metal in a certain way. For closed die castings, which are the majority of castings, this mold is cut into two separate metal blocks; in order to form a complete mold, the tooled blocks are placed together with cavities aligned. Once the die has been created, it is sprayed with a lubricant that helps control its temperature and assists in part removal once the cast is complete. The die is then closed, and molten metal is poured into the shot sleeve and injected into the die under high pressure by a plunger. Pressure is maintained within the die until the cast has solidified, then the die is opened and ejector pins push out the solidified "shot." This metal piece is considered a shot until the excess material that has solidified around it during casting is removed. This excess material typically consists of sprue, gate, runners and flash that have formed in channels leading to the die mold and possibly in leakage areas between the mold cavities. The cast part is tooled and deburred to remove this excess and is sometimes put through additional secondary processes such as surface finishing, plating and CNC machining.

Die casting is a high volume, low cost means of forming relatively complex metal parts. Because this forming method does not create a uniform molecular structure or grainflow in the same way that forging and extruding processes do, die cast parts do not have high strength and often have microfractures and grainflow inconsistencies that can lead to part failure or breakage under strain, corrosion or heat stress. For this reason, die cast parts are often heat-treated and carefully tested after manufacturing. There are some cases in which a die cast metal part is less appropriate for a task than a forging is. Consistently, though, die castings can be applied and relied on for their strength and durability if installed and maintained correctly. It is also important to carefully pair the correct die casting with its application; choosing the wrong metal for a die casting application can be catastrophic, particularly when it comes to engines and heavy machinery. A combination of careful design, materials selection, installation and maintenance will ensure the continued reliable operation of a die cast part for many years.

Die Castings Manufacturers
Die Castings Manufacturers
Die Castings Manufacturers - A&B Die Casting
Die Castings Manufacturers - A&B Die Casting
Die Castings Companies
Die Castings Companies
Die Castings Companies- A&B Die Casting
Die Castings Companies- A&B Die Casting

Different Types of Die Casting Process

Die casting is a standard metal casting process, in which melted metal is used for forming a molded cavity. This molded cavity is made using two toughened steel dies having shape and size quite similar to an injection mold.

Die casting is a very popular industrial and manufacturing process for creating casting metal products. Mainly, there are two types of die casting processes, both involving machines of a variety of designs. In both the processes, molten metal is forced into the mold at a very high pressure.

This process is called die casting. It is the most convenient industrial process for quick production of accurate metal parts - that are used in a large number of machines and applications. Following are a few other benefits of die casting process -

High-quality parts: The parts created through the die casting process have superior finishing, along with fine edges. Additionally, through die casting, the surface finish of the product can also be chosen to meet the specific application requirement.

High Accuracy: Two hand-carved parts cannot be similar. With die casting, uniformity even in a mass production exercise can be assured. You can create accurate parts - no matter how many there are.

Quick Production: Casting metal parts into desired shapes with hands would take a lot of time. Using die cast tools you can minimize this time involvement.

Create Any Shape and Design: You can design and engineer your die casting tools. This allows you to create parts of any size, shape, finish, and surface texture.

Die casting products are used in applications across industries. Applications that work on metal components have parts made through die casting processes. For different industries and applications, parts are made from diverse die casting processes. The below sections list some of the most popular die casting methods -

Hot-Chamber Die Casting Process

Hot-chamber process is a popular process that employs a cylinder as chamber to regulate the injection mechanism. Sometimes, it is also referred to as gooseneck casting. The cylinder or chamber is completely filled with molten metal and the gooseneck system brings the liquefied metal into the die cavity.

This process allows quick formation of mold injection. That is a great convenience. However, the quick processing also brings many chances of defects and earlier corrosion in design.

Cold-Chamber Die Casting Process

In the design idea, the cold chamber die casting process is quite close to the previously discussed hot-chamber die casting process. However, with this method, a manufacturer tries to increase the corrosion resistance, rather than focusing on increasing the production. In the cold chamber process, the molten metal is poured into the injection manually. This method of part forming is ideal for the metals that have high melting point, such as aluminum.

Low Pressure Die Casting Process

Most die casting process are completed in high-pressure cylinders. Though, there is also a method that is known as low pressure die casting, which is suitable for the creation of aluminum components and the wheels of automobiles.

Apart from these, some other die casting processes are vacuum die casting, squeeze die casting, and semisolid die casting.

All You Need To Know About Die Casting

Die casting is a manufacturing process for creating metal parts of accurate and desired size/shape. Using well-designed die casting tools, perfectly designed and shaped metal parts can be created to meet the demand of manufacturing businesses across industries. Ideally, melted metal is forced into reusable dies under a high pressure to produce castings that are accurate in design and surface finish.

Production of Die Casting

The production of die castings is a multi-stage process. In the first stage, a steel mold is made that is strong enough to produce thousands of castings, consecutively.

Typically, dies are usually made from alloys (steel) in at least two sections - named as, the fixed die half and the ejector die half. The fixed half is fixed on the side of the molten metal injection system, while the other half is the movable part that is close clamped by the die casting machine.

Melted metal is injected into the die halves tightly clamped together with the help of a die casting tool. This clamping creates a room, in which the liquefied metal solidifies. Then, the two sections are separated again to take out the product. Sometimes, these halves can be simple in design. And, many a times, they can be moveable slides. The design of the sections majorly depends on the type of the casting product.

Machines and Tools Used for Die Casting

No matter how intelligent and advanced your die casting machine is, what is important in the metal part formation process is the sound and secure locking of the die sections. Generally, the rigidness of clamping depends on the surface area of the casting and the pressure that is used to insert the molten metal into the die.

Sometimes, hydraulic cylinders are used in the process to signify the pressure to accomplish a superior and stronger locking. Many die casting manufacturers also use a toggle mechanism to ascertain that the pressure being applied is accurate for the final casting product. Some also use safety interlock system to disallow the opening of die during the production cycle.

Most die casting machines work on two mechanisms - hot chamber and cold chamber. However, the designs of both the types are quite similar. But, their processes differ.

Hot Chamber Machines

Hot chamber die casting machines are used for creating the castings from zinc and low melting point alloys - that do not bring wears to metal pot, chamber, or cylinders.

The injection mechanism in these machines is completely dipped in the molten metal. Hot chamber machines are known for quick operation and casting production.

Cold Chamber Machines

As said earlier that both types of machines are quite close in design; however, they are dissimilar in many of their features. One such feature is -the melted metal is dipped into a cold chamber with the help of an automatic ladle (sometimes, manually).

Another varying aspect is the injection pressure in these machines could cross the 10,000 psi mark. When working with copper alloys, you can take the pressure to over 15,000psi level.

Tips on Designing Dies for Die Casting Metal Processes

Die casting is a widely used metal manufacturing process. The method makes it possible for a metal fabrication business to create parts of different size, shape, measurement, strength, and surface finish with great precision. To create metal castings, the first step is to create dies with precise size and shape. This article lists a few tips on designing dies for creating die castings-

  1. Identify all the parts that can be created easily. If needed, you could use ribs to allow the part to have the maximum possible strength.
  2. Note all the requirements specified by your client. Ask your designers to be careful with the thin sections; these areas may need strengthening to prevent breakage.
  3. Usually, dies have two sections. Try to maintain uniformity in sections as much as you can. Any variation in design can directly influence the final casting. Additionally, having uniformity in the sections would help you circumvent unwanted surface tension in the product.
  4. Unless required, there is no point in making complex designs and shapes. Try to keep the shapes simple. Remember, you have to exclude additions and designs that are unnecessary.
  5. Make sure that the dies have adequate holes or recesses. They will help you save raw materials. The cost of tooling can also be saved this way.
  6. For convenience, you can include a slight crown above the moveable die section. It will help at the time of removing the clamping from the sections after the molten metal has solidified.
  7. Ensure that the sections have strategically designed cores. The cores allow easy withdrawal of toughened metal from dies. They also help in avoiding complexities in design and construction. The size of the cores should be adequate to avoid wastage of material.
  8. The length of the cores should not be too small. Small cores can easily turn or can get damaged while you try to remove sections after the toughening of the metal.
  9. Some die casting manufacturers prefer creating small holes in die casting. Most of them use drilling machines to make punctures in the casting. It is more convenient and cost-effective than designing cores.
  10. Ensure sufficient space between the sidewalls and the cores. An ample space allows effortless and safe removal of castings from the die. It also reduces the chances of damages.
  11. Check for the sharp corners inside and outside. However, sometimes, edges and corners are purposely designed to achieve a special design.
  12. Do not forget to add ejector pins in the castings. Ejector pins enable you to remove the casting from the sections. They should be placed strategically and should be a part of the designer. This needs to be done at the design phase because they leave marks on the metal casting. Such marks can make the casting unappealing.
  13. Last but not the least, all the inserts, including ejector pins, edges, and cores should be held firmly in the die casting.

Advantages of Die Casting

Die casting is a popular method of metal part manufacturing. In this process, liquefied metal is used for creating a perfectly molded cavity. The melted metal is poured into the die (mold) that has the exact shape and size that the manufacturer wants the casting to have. With this method, metal parts in bulk numbers can be created with great accuracy.

There are many benefits of the die casting metal process -

No Delays in Production - The process does not take much time to complete. The molten metal is forced into the die. Then, it is allowed to cool down at normal temperature. As the metal solidifies, the two parts of the die are separated to take out the hardened casting. No matter how big the order from your client is or how sophisticated its design is, with the die casting method, you can efficiently meet production and delivery deadlines.

Cost-effective - Most die casting manufacturers have a large number of reusable dies, which they use in their production repeatedly. Unlike the injection molding process, the dies are not discarded after the use. This is the reason why products manufactured through the die casting process are more economical than the products made using other metal parts manufacturing methods.

In addition to this, the die casting process does not require the deployment of machines. Sometimes, machines could be used, but only for injecting the molten metal and clamping the sections of the dies. Reusability of dies and less or no requirement of machines help manufacturers keep costs down.

Versatility in Design - You can form a die of a desired shape and size and use it to produce metal castings as demanded by your client. Most of the time, dies are created in two sections; however, sometimes, dies can be of three to four parts. An intelligent designer can create a variety of designs and there is no limit to it.

Complexity Becomes Convenience - Die casting is a simple method, but it can be used to produce complex shapes easily and conveniently.

Durable Parts - Through die casting manufacturing process, parts with higher strength can be created. While the metal is in the liquid state, some add-ons can be introduced (such as a stronger metal or alloy) to increase the strength and durability of the casting.

Metal Parts with Visual Appeal - Your designers can design a resourceful die to create parts of nice visual appeal. Other metal manufacturing processes may not be able to offer the perfectness in design that die casting does.

Multiple Finishing Techniques - As mentioned earlier, with the die casting method, parts can be produced with smooth or textured surfaces. You can apply desired finishing on the surface of the casting to suit the application requirement.

Dimensional Accuracy - Die castings are made from thoroughly-designed dies. This helps the manufacturers to achieve dimensional accuracy in the product. The parts have the exact measurement as asked by the client.

Die casting parts are durable and resistant to wear and tear. They also have a great heat resistance, apart from having better finishing and surface strength.

  • Alloy castings are metal shapes made by a metal formation machine called a caster. Alloys are combinations of at least two metals and sometimes non-metals like carbon and silicon.
  • Aluminum casting are die castings made from aluminum.
  • Aluminum die castings are commonly used in the production of hardware and tools because of the great resistance of aluminum castings to corrosion and high temperatures as well as their conductivity. In addition, aluminum castings are used in applications requiring the production of intricate part features and components.
  • Automotive castings which include engine blocks and cylinder heads as well as brake and suspension components, are increasingly being manufactured out of lightweight material, such as aluminum, to economize fuel consumption by decreasing the overall weight of the vehicle.
  • Brass castings are used in the architectural and construction industries and in decorative applications, such as doorknobs.
  • Bronze castings are used in applications requiring high strength, making them ideal for use in the architectural and construction industries.
  • Cold chamber die castings are cast metals that are formed in a cold chamber as opposed to a hot chamber.
  • Copper die castings are used in applications requiring exceptional strength and resistance to corrosion. Copper castings consist of brass and bronze castings.
  • Die casters shape metal by putting pressure on molten metal in a die.
  • Die casting design is the process of planning and deciding the configuration of a die cast product.
  • Gravity die castings are produced by pouring molten aluminum into a metallic tool at a casting temperature of 750ยบ. Gravity die castings have good tolerances and surface finishing.
  • High pressure die castings have very thin walls. The metal enters the die cavity at high speeds and under great pressure, which increases the chance of porosity.
  • Hot chamber die castings are cast metals that are formed in a hot chamber as opposed to a cold chamber.
  • Lead die castings offer great corrosion resistance and are used in the production of parts in the plumbing industry. Lead castings and tin castings also provide close production tolerances but are generally not as strong as other die cast metals.
  • Low pressure die castings are formed when metal from an airtight furnace is transferred into a metallic tool through a rising tube. Low pressure die casting is suitable for relatively small lot sizes and for applications in which heat treatment is needed to improve the mechanical properties.
  • Magnesium die castings are particularly useful in applications where weight is a factor. Magnesium die castings are very lightweight and cost-effective, especially in comparison to other die cast metals.
  • Metal castings are metal impressions made with molds.
  • Pressure die castings are metal castings that have been formed under carefully controlled pressure conditions; all die castings can be considered pressure die castings.
  • Zinc die castings are often used in the production of small parts for the electronics and automotive industries. Zinc castings lend themselves well to secondary operations such as painting and plating.

Die Casting Terms

Automation - Industry term commonly used to describe the mechanization of various aspects of die casting process.

Biscuit - An excess of molten metal that is leftover in the shot sleeve of a cold chamber die casting machine. Biscuits are considered part of the cast shot and are removed from the die with the casting. 

Blister - Die casting deformation consisting of a gaseous bubble on the surface of the casting and a hole in the casting underneath the bubble. 

Blow holes - Voids or pores that may occur due to entrapped gas or shrinkage during solidification, usually evident in heavy sections (see porosity).

Cavity - The recess or impressions in a die in which the casting is formed.

Cold chamber machine - A type of die casting machine in which the metal injection mechanism is not submerged in molten metal.

Checking - Fine cracks on the surface of a die that produce corresponding raised veins on die casting. Caused by repeated heating of the die surface by injected molten alloys. Also called heat checking.

Die lubricants - Liquid formulations applied to the die to facilitate casting release and prevent soldering.

Dimensional stability - Ability of a component to retain its shape and size over a long period of service.

Draft - The taper given to walls, cores and other parts of the die cavity to permit easy ejection of the casting.

Ejector marks - Marks left on castings by ejector pins.

Ejector pins - A rod that forces the casting out of the die cavity and off of cores.

Ejector plate - A plate that actuates the ejector pins attached to it. 

Fillet - Curved junction of two surfaces. For example: walls that would meet a sharp angle.

Flash - Excess metal on a die cast part extending past the parting line of the die set, which blocks metal from flowing past the die lines and filling the die impressions. 

Gate - Passage for molten metal that connects runner with die cavity. Also, the entire ejected content of a die, including castings, gates, runners sprue (or biscuit) and flash.

Growth - Expansion of a casting as a result of aging or of intergranular corrosion, or both.

Heat checking - (See checking)

Hot chamber machine - Die casting machine in which the pressure chamber is subjected to the molten metal through immersion. Hot chamber machines are used in the die casting of metals with low melting points, such as zinc die casting, copper die casting and magnesium die casting.

Impact strength - Ability to resist shock as measured by a suitable testing machine.

Ingot -
Metal or alloy cast in a convenient shape for storage, shipping or remelting.

Injection -
The processes of forcing molten metal into a die.

Insert -
A piece of material, usually metal, which is placed in a die before each shot. Molten metal is cast around it to produce certain features on and within the die cast part.

Loose piece, knockout -
A type of core (which forms undercuts) that is positioned in, but not fastened to, a die. It is so arranged as to be ejected with the casting from which it is removed. It is repeated for the same purpose.

Metal saver -
Core utilized to prevent sections of excessive thickness from occurring and to reduce the amount of metal used in a metal casting.

Multiple cavity die -
A die having more than one duplicate impression.

Overflow -
An opening or cavity on the parting line of the die outside of the main die cavity into which unacceptable metal flows during the shot process. Reasons for metal unacceptability include improperly heated metal and metal that contains impurities.

Parting line -
A line along the surface of a die casting reflecting the small space between the die halves; also, the mating surface of the cover and ejector portions of the die.

Plunger -
Ram or piston that forces molten metal into a die.

Porosity -
Very small voids or pores in cast metal parts resulting from trapped gas or shrinkage during solidification.

Process control -
Where parameters of a process are studied and correctly applied in the manufacturing process to produce high quality parts.

Runners -
Horizontal mechanisms connected to the sprue that transfer the molten metal from the sprue to the mold.

Shot -
The process in which the metal is poured into the die. The shot may also refer to the die cast part as it exists as a cast before secondary operations are performed to remove flash and to fix imperfections in the casting.

Shrinkage, solidification -
Dimensional reduction that accompanies the freezing (solidification) of metal, passing from the molten to the solid state.

Shrink mark -
A surface depression that sometimes occurs next to a heavy section that cools more slowly than adjacent areas.

Slide -
The portion of a die arranged to move parallel to die parting. The inner and end forms a part of the die cavity wall that involves one or more undercuts and sometimes includes a core or cores.

Soldering -
Adherence of molten metal to portion of the die.

Sprue -
Mechanism with which the molten metal first makes contact during the shot process. The sprue transfers the molten metal to the runners.

Trim die -
A die for shearing or shaving flash from a die casting.

Trim -
The process in which overflow, flash and other parts are removed from the die cast part or shot.

Unit die -
A die interchangeable with others in a common holder.

Undercut -
Recess in the side wall or cored hole of a casting disposed so that a slide or special form of core (such as a knockout) is required to permit ejection of the casting from the die.

Vent -
An orifice in the casting die that facilitates the release of air from the die cavity into the atmosphere to prevent casting imperfections, such as porosity.

Void - A large pore or hole within the wall of a casting usually caused by entrapped gas. A blow hole.

Waterline - The channel in the casting die into which water flows to precipitate the cooling of the die casting.

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