Die casting process: What you need to know
When a technical component needs to function precisely, be reliably repeatable, and be economically manufactured, the die casting process offers a reliable solution. We produce functional aluminum cast parts that meet the demands of development, design, and series production equally.
How the die casting process works
The die casting process is an industrial casting process. Liquid aluminum is injected into a precisely made die-casting mold at high speed and pressure. After a short solidification period, a dimensionally accurate casting with high density, stable surface, and clear contour fidelity is produced.
Typical die casting machines operate with pressures between 150 and 1200 bar. The filling speed can reach several meters per second. Solidification occurs within seconds. This allows intricate geometries, thin wall thicknesses, and functional details to be implemented precisely.
Hot or cold chamber? These methods are available
Cold chamber process for demanding aluminum parts
In the cold chamber process, the liquid aluminum is melted outside the casting machine and is manually or automatically metered into the casting chamber. This process is ideal for aluminum alloys that need to be processed at high temperatures. It prevents the casting machine from being constantly exposed to the liquid metal, thereby reducing tool wear and thermal stress.
We use only the cold chamber process for aluminum as it is best suited for functionally integrated, dimensionally accurate components.
Hot chamber process for zinc and magnesium in fast cycles
For materials like zinc or magnesium, the hot chamber process is used. Here, the casting chamber is directly in the melt bath. The cycle is faster; however, the stresses on the machine and the tool are higher.
Advantages of the die casting process
The die casting process offers a combination of dimensional accuracy, reproducibility, and cost-efficiency that is hardly matched by any other manufacturing process. Particularly for medium to large production quantities, the process fully exploits its strengths, both technically and in terms of manufacturing costs.
High dimensional accuracy with complex geometries
Due to the high injection pressure and precisely manufactured tools, even delicate details and tight tolerances can be reliably reproduced.
Consistently accurate series production
Once the component is approved, we deliver consistent quality – for thousands or hundreds of thousands of parts.
Short cycle times and high output
The aluminum solidifies within seconds. This means larger quantities can also be manufactured economically.
Function and form in one step
With the ability to directly integrate technical features into the component, many downstream processing operations are eliminated. This saves time, reduces error sources, and simplifies assembly.
Suitable for demanding applications
Thanks to its high strength, good thermal conductivity, and the possibility of alloy adjustments, aluminum die casting is suitable for high-demand parts in industry, vehicle engineering, or electrical engineering.
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From CAD model to casting: Your project workflow at SBV Stahltechnik
We carefully examine every customer request for technical feasibility and economic efficiency. The focus is not only on the casting itself, but on the entire process chain from consulting to the idea through to ready-to-install delivery. The process is as follows:
Inquiry and data review
You send us your drawings and 3D data as well as information about the area of application, quantity & material. We evaluate whether the component is designed appropriately for manufacturing or if adjustments are required.
Technical consultation
Our casting specialists examine geometry, material selection, and functional requirements. If necessary, we provide recommendations for optimizing the geometry or selecting the appropriate aluminum alloy for your application.
Prototypes and pre-series
In aluminum die casting, prototypes can only be realized via a tool. We therefore manufacture initial pre-series parts directly from the production tool or from a specially simplified pre-series tool. This way, geometry, function, and process capability can be verified early on before series production starts.
Series production with our partner in Asia
Production takes place through our partners in Asia. We fully handle the technical coordination, quality assurance, and logistical coordination. This way, you receive your components reliably and on schedule from a single source.
Quality control and documentation
Before delivery, every casting is inspected. You receive not just a component, but a secure system part with tested properties.
Application areas of die casting
Automotive and vehicle construction
Die casting is indispensable in the automotive sector. Engine components, gearbox housings, structural components, or enclosures for electronic components are manufactured with high precision and dimensional accuracy. The process allows for the production of lightweight, stable components that withstand the high demands and safety requirements of this industry.
Machine and plant engineering
Complex housings, pumps, valves, or connections can be economically manufactured in die casting. High form accuracy reduces the need for post-processing, while the material variety provides solutions for a wide range of applications in mechanical engineering.
Household and sanitary technology
In the sanitary and household appliance sector, fittings, housings, and functional parts are manufactured using the die casting process. Here, corrosion resistance, precise fit, and economical series production are particularly convincing.
Electrical engineering & electronics
Die casting offers excellent shielding properties against electromagnetic interference (EMI). Therefore, the process is often used for enclosures of control units, sensors, or LED lights. The high surface quality also ensures optimal functionality and longevity.
Medical technology
In medical technology, precision and hygiene are crucial. Die casting allows the manufacture of parts with smooth surfaces and tight tolerances – ideal for device housings, brackets, or fine mechanical components.
Aerospace
In aviation, weight and durability are critical. Die casting enables the production of complex lightweight components that meet high safety and quality standards.
Why aluminum is the ideal material for die casting
Aluminum combines low weight with high strength, good thermal conductivity and excellent castability. This makes it the preferred material for many technical applications. However, not every aluminum alloy is the same. We recommend the appropriate alloy based on load, environment, and processing.
Commonly used alloys:
- AlSi12 for delicate structures and smooth surfaces
- AlSi10Mg for mechanical stress and processing needs
Do you want to know if your component is suitable for the die-casting process?
Then let’s examine together how your requirements can be technically and economically implemented.
