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Advantages and disadvantages of die casting - LinkedIn

Author: Ada

Jul. 28, 2025

Advantages and disadvantages of die casting - LinkedIn

Die casting is a manufacturing process that uses high pressures to force molten metal from a crucible into a metal jacket. The material is then injected through a rod into a preformed mold (die). Once injected, the part is cooled, solidified and removed from the mold. This process is used for both parts and ingots.

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The manufactured parts are characterized by high uniformity, good surface finish and high dimensional accuracy. The dimensions of the parts vary depending on the specifications. Weights range from a few grams for the smallest parts to several tons. We can even obtain extremely thin-walled parts. In fact, most of the parts do not need the final machining process or need very light machining.

We have the support of factories equipped with all the necessary tools to obtain the desired product at the best price. Starting with the melting of material, injection, solidification and expulsion of the finished part. In addition, we guarantee that the necessary post-treatments are carried out on the parts.

High efficiency. Die casting machinery has a high productivity compared to other processes.
The alloys used in die casting have a long service life, easy to machine and automate.
Final quality. The dimensional accuracy of the casting is high, generally equivalent to 6 ~ 7, even up to 4.
Good surface finish, which means that further finishing will not be necessary; lowering prices per part.
High strength and hardness, generally higher than sand casting by 25 ~ 30%, but extended, the rate is reduced by about 70%.
This process allows complex thin-walled castings. For example, current zinc alloy castings have a minimum wall thickness of 0.3 mm; aluminum alloy castings up to 0.5 mm; the minimum casting hole diameter is 0.7 mm, and the minimum pitch is 0.75 mm.

The main disadvantage of die casting is its high cost. Both the necessary casting equipment and the dies and related components are very expensive compared to most other casting processes.
The process is limited to high-flow metals. Fluidity failures can lead to increased scrap rates, and scrap costs in die casting are high.
Die casting involves a large number of parts, so repeatability issues are especially important.
Weights of castings have previously been limited to between 30 grams (1 oz) and 10 kg (20 lb), but as of , parts up to 80 kilograms have become possible.
In the standard die casting process, the final part will have a small amount of porosity. This prevents any heat treatment or welding, because the heat causes the gas in the pores to expand, leading to micro-cracks inside the part and surface exfoliation. However, some companies have found ways to reduce the porosity of the part, which allows welding and heat treatment to be limited.

High Pressure Die Casting Advantages & Disadvantages - Blog

High pressure die casting is a fast and precise method for creating aluminium or zinc components. It’s used by industries with specific requirements for appearance and dimensional tolerances, Here’s an overview of the process itself and a look at the pros and cons.

Process of High Pressure Die Casting

Manufacture of the mould: A hardened steel die is carefully machined to create a cavity in the shape of the final product, along with a running system to inject the molten metal.

Setting up the die: The die is mounted on a die casting machine (DCM) and pre-heated. The larger the production run the more economic the process as some set up processes can take time.

Melting the Metal: The alloy used for the part is melted in an electric or gas-powered furnace until it becomes liquid.

Injecting the Metal: The molten alloy is then injected into the die at high pressure. This high pressure ensures complete cavity filling and accurate mould replication.

Cooling the Metal: The molten metal cools rapidly and solidifies into the mould’s shape with additional pressure to compensate for contraction.

Ejection: The two halves of the die are separated, and the finished part is ejected using pins or ejector plates. Further finishing processes may be needed.

Recycling: Excess material is trimmed and recycled for the next production cycle.

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Pros of High Pressure Die Casting

Fast and Cost-Effective Production: HPDC is an efficient process. It can produce large quantities of parts in a short time frame, often making it the most cost-effective option for high-volume production runs. The speed and precision of casting cycles ensure reduced waste, increased efficiency, and ultimately lower cost per unit over time.

Thin-Walled Components: The high pressure involved in this process allows for casting of extremely thin-walled components - as thin as 1mm. This feature is beneficial for creating lightweight parts that still maintain high strength and durability. Industries such as aerospace, automotive, and electronics benefit from this feature as they often require light, robust parts.

Smooth Surface Finish: HPDC produces components with smooth surfaces that are ideal for applying coatings or additional finishes. This reduces the need for secondary machining processes, saving time and money. It also contributes to the aesthetic appeal of the finished product, which is particularly beneficial for consumer goods.

Cons of High Pressure Die Casting

Porosity Issues: One common problem associated with HPDC is porosity - the formation of tiny holes or voids in the cast part due to trapped gas. Porosity can weaken the mechanical properties of the cast, limit its lifespan, and compromise its appearance. While careful design and process control can minimise this issue, it cannot be eliminated completely.

Limited Heat Treatment: The porosity caused in HPDC also restricts the ability to fully heat-treat components post-casting. Heat treatment, often employed to increase the strength and durability of metal parts, may not be uniformly effective due to the presence of porous areas.

High Start-up Costs: HPDC involves significant initial costs, particularly for tooling and setup. These costs can be limiting for small-scale production or prototyping. However, these costs are often offset over time in high-volume production runs due to the lower unit costs.

Why choose MRT Castings?

If high pressure die casting suits your application, consider MRT Castings for reliable component production.

We offer:

Machines with locking forces between 220 and 530 tonnes, providing flexibility in size and weight.

Computerised shot control, automatic ladling, die-spray, casting extraction, and cooling for enhanced repeatability and productivity.

Accessibility for small quantities: Our optimised tooling preparation and setup operations cater to customers requiring small runs.

Choose MRT Castings as your trusted partner for high-quality, precision high pressure die casting, whatever your order size.

If you want to learn more, please visit our website Die Casting Manufacturer.

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