Our High Pressure Die Casting (HPDC) Services
Looking for a casting technology that blends high production efficiency, precision components, and cost-effectiveness? High Pressure Die Casting (HPDC) delivers exactly that. From automotive parts to medical devices, our HPDC services combine advanced manufacturing techniques, top-tier die casting materials, and strict quality assurance to turn your designs into durable, lightweight products. Whether you need custom solutions or large-scale production, we’re your trusted partner for all HPDC needs.
What Is High Pressure Die Casting (HPDC)?
At its core, High Pressure Die Casting (HPDC) is a casting technology that forces molten metal into a reusable steel mold (called a die) under high pressure—typically between 1,000 and 15,000 psi. This process creates complex, net-shape components with consistent quality, making it a cornerstone of modern manufacturing.
The HPDC process overview revolves around four key stages: melting metal, injecting it into the die, cooling the part, and ejecting the final component. Unlike other casting methods, HPDC excels at high-volume production, thanks to its speed and repeatability. For anyone new to this field, understanding die casting fundamentals—such as how metal injection pressure and die design impact part quality—is essential to leveraging its full potential.
Our Capabilities: Delivering Top-Tier HPDC Solutions
At Yigu Technology, our HPDC capabilities are built to meet the diverse needs of global industries. We don’t just offer die casting services—we provide end-to-end solutions that combine technical expertise with flexibility. Here’s a breakdown of what we bring to the table:
| Capability Area | Key Offerings |
| Production Capacity | 50,000–500,000 parts per month; 24/7 operation for urgent projects |
| Technical Expertise | Team of 20+ certified engineers with 10+ years of HPDC experience |
| Quality Assurance | ISO 9001 & IATF 16949 certification; 100% dimensional inspection for critical parts |
| Custom Solutions | Design support for die optimization; material selection tailored to your needs |
| Project Management | Dedicated account managers; real-time production tracking via our portal |
Whether you need a small batch of custom components or a large-scale production run, our capabilities ensure on-time delivery and consistent quality.
The HPDC Process: Step-by-Step Breakdown
The HPDC process is a well-orchestrated sequence of steps that ensures precision and efficiency. Each stage plays a critical role in the final part’s quality, from die preparation to post-processing. Here’s a detailed look:
- Die Preparation: First, the two halves of the steel die are cleaned and sprayed with a lubricant. This prevents molten metal from sticking and helps with cooling. The die is then clamped tightly together to withstand the high injection pressure.
- Metal Injection: Molten metal (usually aluminum, zinc, or magnesium alloy) is pushed into the die cavity at high speed (up to 50 m/s) and pressure. This metal injection step ensures the metal fills every detail of the die, even for complex geometries.
- Cooling and Ejection: Once the die is filled, the metal cools and solidifies quickly (typically in 10–60 seconds). The die is then unclamped, and ejector pins push the finished part out.
- Post-Processing: After ejection, excess material (called flash) is trimmed from the part. Additional steps like surface treatment or machining may follow, depending on the application.
Quality Control: Every batch undergoes inspection—including dimensional checks and material testing—to meet tolerance standards and ensure no defects.
Materials Used in HPDC: Selection and Properties
Choosing the right die casting materials is critical to achieving the desired strength, weight, and cost for your part. The most common alloys in HPDC are aluminum, zinc, magnesium, and copper, each with unique properties. Below is a comparison of their key characteristics:
| Alloy Type | Density (g/cm³) | Tensile Strength (MPa) | Melting Point (°C) | Key Advantages | Common Applications |
| Aluminum Alloys | 2.7 | 200–350 | 580–650 | Lightweight, corrosion-resistant, high recyclability | Automotive parts, electronics housings |
| Zinc Alloys | 6.6–7.2 | 180–300 | 380–420 | Low melting point (energy-efficient), high precision | Consumer goods, hardware |
| Magnesium Alloys | 1.8 | 170–280 | 650–670 | Lightest die casting metal, good strength-to-weight ratio | Aerospace components, medical devices |
| Copper Alloys | 8.9 | 300–600 | 1,085 | Excellent conductivity, high strength | Electrical connectors, industrial parts |
Our team provides material selection support to match your project’s requirements—whether you need a lightweight alloy for aerospace or a durable one for industrial equipment.
Surface Treatment: Enhancing HPDC Part Performance and Aesthetics
Surface treatment is a key step in maximizing the value of HPDC parts. It improves durability, corrosion resistance, and appearance, while also meeting industry-specific standards. Below are the most common surface finishing methods we offer:
- Anodizing: Ideal for aluminum parts, this process creates a hard, protective oxide layer. It enhances corrosion resistance and allows for color customization (clear, black, or bronze).
- Plating: Methods like chrome or nickel plating add a shiny, durable coating. Plating is often used for consumer goods or parts that need a decorative finish.
- Painting: We use high-quality, industrial-grade paints that resist chipping and fading. Painting is suitable for parts requiring specific colors or branding.
- Coatings: Ceramic or powder coatings provide extra protection against wear and chemicals. They’re popular for industrial equipment and automotive undercarriage parts.
- Polishing: Creates a smooth, mirror-like finish for parts where aesthetics are critical, such as decorative components or medical devices.
Each surface enhancement method is chosen based on the material, application, and customer needs—ensuring your part looks and performs its best.
Tolerances in HPDC: Ensuring Dimensional Accuracy
Casting tolerances and dimensional accuracy are non-negotiable in HPDC, especially for industries like automotive and aerospace where parts must fit perfectly with other components. At Yigu Technology, we adhere to strict tolerance standards (including ISO 8062 and DIN 1688) to ensure precision.
| Part Feature | Typical Tolerance Range | Measurement Technique Used |
| Length (up to 100mm) | ±0.1mm to ±0.3mm | Coordinate Measuring Machine (CMM) |
| Hole Diameter | ±0.05mm to ±0.2mm | Micrometer or CMM |
| Flatness | 0.1mm per 100mm | Surface Plate with Dial Indicator |
| Parallelism | 0.15mm per 100mm | CMM |
Our quality control team uses advanced measurement techniques—such as CMMs and optical scanners—to verify tolerances for every part. This commitment to precision casting ensures your components work reliably, even in demanding environments.
Advantages of HPDC: Why It’s a Top Manufacturing Choice
HPDC advantages make it a go-to technology for industries ranging from automotive to electronics. Here’s why more manufacturers choose HPDC over other casting methods:
- High Production Efficiency: HPDC can produce hundreds to thousands of parts per hour, thanks to fast cycle times (10–60 seconds per part). This makes it ideal for high-volume orders.
- Precision Components: The high pressure used in HPDC ensures parts have tight tolerances and complex geometries—no extra machining needed for most designs.
- Cost-Effective: Lower labor costs (due to automation) and minimal material waste (scrap is recyclable) make HPDC more affordable than other casting methods for large batches.
- Design Flexibility: HPDC supports intricate designs, including thin walls (as thin as 0.5mm for aluminum) and internal features like holes or ribs.
- Lightweight: Alloys like aluminum and magnesium create lightweight parts, which is critical for industries like automotive (to improve fuel efficiency) and aerospace.
Strength and Durability: HPDC parts have excellent mechanical properties—they’re strong, resistant to wear, and can withstand harsh conditions (like high temperatures or corrosion).
HPDC Applications by Industry
HPDC applications span nearly every major industry, thanks to its versatility and performance. Below are some of the key sectors we serve and the parts we produce:
| Industry | Common HPDC Parts |
| Automotive Industry | Engine brackets, transmission cases, wheel hubs, electric vehicle (EV) components |
| Aerospace | Cabin components, engine parts, structural brackets (using magnesium alloys) |
| Electronics | Laptop housings, smartphone frames, heat sinks, connector shells |
| Consumer Goods | Power tool casings, kitchen appliance parts, toy components (using zinc alloys) |
| Industrial Equipment | Pump housings, valve bodies, gearboxes, conveyor system parts |
| Medical Devices | Surgical instrument components, diagnostic equipment housings (using corrosion-resistant alloys) |
| Telecommunications | Router housings, antenna parts, fiber optic connector bodies |
No matter your industry, we can tailor HPDC solutions to meet your specific needs—from small, precise parts to large, structural components.
Manufacturing Techniques in HPDC: Innovation and Efficiency
At Yigu Technology, we use cutting-edge die casting techniques to optimize the HPDC process. Our focus on innovation ensures we deliver high-quality parts at competitive prices. Here are the key techniques we leverage:
- Automation: We’ve automated key steps like die lubrication, metal injection, and part ejection using robotic arms. This reduces human error, speeds up production, and ensures consistency.
- Tooling Excellence: Our die design team uses 3D modeling software to create high-performance dies. We also use heat-treated steel for dies, which extends their lifespan (up to 1 million cycles for aluminum alloys).
- Injection Molding Integration: For parts that need plastic components, we offer overmolding—combining HPDC metal parts with plastic in a single process. This saves time and reduces assembly costs.
- Lean Manufacturing: We follow lean principles to eliminate waste—from reducing material scrap (we recycle 95% of HPDC scrap) to optimizing production schedules for faster delivery.
Process Optimization: Our engineers use real-time data (from sensors in dies and injection machines) to adjust parameters like pressure and temperature. This continuous improvement approach ensures we’re always refining our process for better quality and efficiency.
HPDC Case Studies: Our Success Stories
Our HPDC case studies showcase how we solve complex manufacturing challenges for our customers. Here are two examples:
Case Study 1: Automotive EV Component Production
Challenge: A leading EV manufacturer needed a lightweight, high-strength battery housing. The part required tight tolerances (±0.1mm) and corrosion resistance.
Solution: We used an aluminum alloy (A380) for its lightweight and corrosion-resistant properties. Our team optimized the die design to reduce wall thickness (to 2mm) while maintaining strength. We also added an anodizing surface treatment for extra protection.
Result: We produced 100,000 housings per month with zero defects. The part was 20% lighter than the customer’s previous design, improving the EV’s range by 5%.
Case Study 2: Medical Device Component
Challenge: A medical device company needed a precision component for a diagnostic machine. The part required biocompatibility, tight tolerances (±0.05mm), and a smooth surface finish.
Solution: We chose a magnesium alloy (AZ91D) for its biocompatibility and lightweight properties. We used advanced measurement techniques (CMMs) to verify tolerances and added a polishing surface treatment for a smooth finish.
Result: The component met all medical standards (ISO 10993) and performed reliably in the diagnostic machine. The customer reduced their production costs by 15% compared to their previous supplier.
Why Choose Us for Your HPDC Needs?
When you partner with Yigu Technology for HPDC, you’re not just getting a supplier—you’re getting a collaborator. Here are our unique selling points that set us apart:
- Quality Commitment: We’re ISO 9001 and IATF 16949 certified, and we follow strict quality control processes to ensure every part meets your specifications.
- Expertise: Our team of engineers has 10+ years of experience in HPDC. We offer design support, material selection guidance, and troubleshooting to help you optimize your part.
- Customer Service: We assign a dedicated account manager to every project. You’ll get real-time updates on production and quick responses to your questions.
- Innovation: We invest in the latest manufacturing techniques (like automation and 3D die design) to deliver better parts faster.
Value-Added Solutions: We offer end-to-end services, including surface treatment, machining, and assembly. This means you can get fully finished parts from a single supplier—saving you time and money.