Custom Components
Die Casting Parts (Aluminum & Zinc) Precision Castings with CNC Finish
We produce high‑quality aluminum and zinc die cast components engineered for strength, dimensional accuracy and surface finish. Our services include die design, vacuum and pressure casting, porosity reduction, secondary CNC machining, and full finishing — ideal for automotive, power electronics, lighting, and industrial hardware.
- Aluminum (ADC12, A380, A356) and Zinc (Zamak 3/5/8) alloys
- Vacuum/low‑pressure casting for low porosity and high integrity
- Tooling, secondary CNC machining, plating, anodize, and assembly
Aluminum Castings
Lightweight, thermally conductive housings and brackets.
Vacuum & Low‑Pressure
Reduced porosity for structural and pressure‑bearing parts.
CNC Finishing
Machined features, tapped holes and precision faces.
What We Make
Aluminum Die Cast Housings & Enclosures
Thermally conductive chassis, enclosures and mounting brackets for power electronics and LED lighting — optimized for weight, stiffness and thermal paths.
Zinc Die Cast Components
High‑precision zinc parts for decorative trims, small structural components and complex geometries with excellent surface finish for plating.
Custom Pressure‑Bearing & Structural Parts
Valve bodies, pump housings and structural brackets requiring low porosity, mechanical strength and consistent dimensional control.
Alloys & Material Selection
We commonly use aluminum alloys (ADC12 / A380 for general die casting, A356 for higher strength/heat treatability) and zinc alloys (Zamak family). Alloy selection is guided by mechanical loads, thermal conductivity, finishing requirements and corrosion environment.
Material guidance
Aluminum for lightweight thermal housings; zinc for fine detail and plated cosmetic parts. We provide recommendations for alloy, temper and post‑cast heat treatment to meet your application needs.
Die Casting Processes
We support hot‑chamber and cold‑chamber die casting depending on alloy and part size. For high‑integrity parts we offer vacuum assisted casting and low‑pressure techniques to minimize gas porosity and improve mechanical properties.
Process options
- High‑pressure cold‑chamber die casting (aluminum)
- Hot‑chamber die casting (zinc alloys)
- Vacuum/low‑pressure casting to reduce trapped gas
- Controlled fill and controlled solidification for directional feed
Tooling & Die Engineering
Tool design includes gating, runner optimization, venting, cooling circuits and vent placements to control shrink, porosity and fill patterns. We design for tool life and maintenance with trials to validate fill and ejection.
Tool life & cavities
Hardened tool steels and optimized cooling extend tool life. Single to multi‑cavity tooling based on volumes and part geometry — we advise on cavity count tradeoffs during costing.
Secondary Machining & Assembly
After casting, parts are deburred, stress‑relieved and can be CNC machined for critical faces, tapped threads, boss features and press fits. We perform EDM, hole re‑aming, counterboring and precision flat machining to achieve production tolerances.
Assembly services
Insert installation, thread‑locking, sealing, and subassembly with fasteners or thermal interfaces as required by the finished product.
Surface Finishing & Coatings
We deliver cosmetic and functional finishes including anodizing (after machining for aluminum), powder coating, wet painting, electroless nickel, nickel/chrome plating for zinc, and conversion coatings for corrosion protection.
Functional coatings
Thermal coatings, corrosion inhibitors, anti‑fingerprint and electrical isolation coatings available depending on end use and regulatory needs.
Typical Specifications & Design Guidelines
Design guidance to reduce porosity, facilitate fill and minimize shrink: uniform wall thickness, proper rib/ boss design, and adequate gating/venting strategies.
Wall Thickness
1.5 — 6.0 mm typical (dependent on part size & alloy)
Draft Angles
0.5° — 2.0° recommended for vertical faces
Shrink
Aluminum: ~1.2% — 1.5%; Zinc: ~0.4% — 0.6% (design for shrink during tooling)
Size Range
Small precision parts to large housings; press size and shot weight determine part max envelope
| Parameter | Range | Notes |
|---|---|---|
| Alloys | ADC12, A380, A356 (Al); Zamak 3/5/8 (Zn) | Selected by strength, thermal, and finishing needs |
| Typical tolerances | ±0.15 mm — ±0.5 mm (post-cast); ±0.02 mm — ±0.05 mm (after CNC finishing) | Tolerances depend on feature and secondary machining |
| Porosity control | Vacuum/low-pressure casting | Recommended for pressure bearings and structural parts |
| Lead time | Tooling 6–14 weeks; prototypes shorter with soft tooling | Depends on complexity & cavity count |
Quality, Inspection & Traceability
We perform dimensional inspection (CMM), X‑ray/CT scanning for porosity on critical parts, hardness testing, metallurgical analysis and full material traceability. Our process control includes SPC, lot traceability and FAI/PPAP for regulated industries.
Non‑destructive testing
X‑ray or CT scanning to detect internal porosity, pressure testing for housings, and helium leak tests when required.
Applications
Automotive & EV
Powertrain housings, gearbox covers, sensor mounts and structural brackets with automotive quality controls.
Power Electronics & Inverters
Thermal enclosures, busbar supports and conductive housings for heat dissipation and EMI control.
Lighting & Consumer Hardware
Die cast light housings, heatsink‑integrated parts and plated cosmetic trims.
Representative Projects
Aluminum Housing for EV Inverter
Vacuum die casting plus CNC finishing produced low‑porosity housing with machined sealing faces and integrated cooling fins; passed leak and vibration testing for automotive release.
Zinc Decorative Trim for Consumer Product
High‑detail zinc casting with nickel plating and secondary polishing for premium surface finish and durability.
Frequently Asked Questions
When should I choose vacuum die casting?
Choose vacuum or low‑pressure casting when internal porosity affects pressure sealing, mechanical strength or fatigue life. Vacuum casting reduces trapped gas and improves integrity.
Can you machine and thread features after casting?
Yes — we provide CNC finishing for critical faces, tapped holes, precision bores and assembly features to achieve production tolerances.
What finishing is best for corrosion resistance?
Aluminum anodize, conversion coatings and appropriate paint/powder coatings provide corrosion protection for aluminum; zinc commonly receives nickel/chrome plating for corrosion and cosmetic needs.
Start Your Die Casting Project
Upload drawings or STEP files and specify target volumes and finish requirements. We’ll return tooling recommendations, porosity mitigation options and a prototype schedule — typically within 24 business hours.
