What Does a Die Casting Factory Do and What Are Its Core Capabilities?

A die casting factory is a specialized manufacturing hub that transforms molten metals into high-precision, complex parts using high-pressure molding technology. Unlike general machining shops, it focuses exclusively on the pressure casting process—turning liquid aluminum, zinc, or magnesium alloys into components that power industries from automotive to medical devices. But what exactly happens inside a die casting factory? What core capabilities set it apart from other manufacturers? And how does it ensure consistent quality for mass-produced parts? This article answers these questions with detailed insights into workflows, technologies, and industry applications.

1. Core Business: The End-to-End Die Casting Workflow

A die casting factory manages every step from raw material to finished part—no external outsourcing required for key processes. The workflow follows a linear, highly optimized sequence:

A. Step 1: Material Preparation & Refining

This stage ensures molten metal meets strict quality standards for fluidity and purity:

• Raw Material Handling: Receive metal ingots (e.g., ADC12 aluminum, Zamak 5 zinc) and sort them by alloy grade to avoid cross-contamination.
• Melting & Temperature Control: Heat ingots in gas or electric furnaces to precise temperatures (680–720°C for aluminum, 380–420°C for zinc). Use digital thermocouples to maintain ±5°C tolerance—critical for consistent flow.
• Refining & Degassing: Remove impurities (oxide slag, foreign particles) via ceramic foam filters (20–30 PPI). For aluminum alloys, use rotary degassing rods (400–600 rpm) to reduce hydrogen content to <0.2cc/100g—prevents porosity in finished parts.

B. Step 2: Mold Management & Preparation

Molds are the “heart” of die casting—factories invest heavily in their design, maintenance, and optimization:

• Mold Design & Manufacturing: In-house mold workshops use CNC machining centers (accuracy ±0.005mm) and EDM (Electrical Discharge Machining) to create molds from high-strength tool steel (e.g., H13 steel). Molds include cooling water channels (spaced 15–20mm apart) to speed up solidification.
• Preheating & Lubrication: Preheat molds to 180–250°C (depending on alloy) to avoid cold shuts. Spray a thin layer of eco-friendly release agent (5–8μm thick) to ensure easy part removal—prevents surface damage.
• Mold Maintenance: Inspect molds after every 5,000–10,000 shots for wear. Repair minor scratches with laser cladding; replace worn cores when dimensional deviation exceeds ±0.1mm.

C. Step 3: Die Casting Molding

The core production stage—high pressure transforms molten metal into finished part shapes:

• Machine Selection: Use hot chamber machines (50–200 tons) for zinc alloys (fast cycle time: 15–30 seconds/part) and cold chamber machines (200–1,200 tons) for aluminum/magnesium alloys (handles high melting points).
• Injection & Solidification: Inject molten metal into mold cavities at 5–150MPa pressure and 2–5m/s speed. Maintain pressure during solidification (holding time: 10–20 seconds) to compensate for shrinkage—ensures part density ≥99.5%.
• Automated Demolding: Use robotic arms (cycle time <5 seconds) to remove parts from molds. This reduces human error and prevents damage to delicate components (e.g., thin-walled electronic housings).

D. Step 4: Post-Processing & Quality Inspection

Finishing steps ensure parts meet customer specifications:

• Trimming & Deburring: Cut off gate residues and runner systems with hydraulic trimmers (for aluminum parts) or laser cutters (for precision zinc parts). Remove burrs with ultrasonic cleaning (Ra <1.6μm surface roughness).
• Surface Treatment: Offer options like anodizing (for corrosion resistance), powder coating (for aesthetics), or plating (for wear resistance). For medical parts, use passivation to meet biocompatibility standards (ISO 10993).
• Quality Testing: Conduct 3 levels of inspection:

1. Visual Inspection: Check for surface defects (scratches, pores) with 10× magnifying glasses.
2. Dimensional Testing: Use CMM (Coordinate Measuring Machine) to verify tolerances (±0.1mm for standard parts).
3. Internal Testing: Use X-ray flaw detection to check for hidden porosity (acceptance standard: ≤2% pore volume).

2. Core Capabilities: What Makes a Die Casting Factory Unique?

Die casting factories stand out from other manufacturers due to 4 key capabilities, tailored to mass production and precision requirements:

3. Key Service Industries: Where Die Casting Parts Are Used

Die casting factories supply critical components to 5 major industries, each with unique requirements:

A. Automotive Industry (40–50% of Revenue)

• Products: Engine mounts, transmission housings, EV battery pack frames, steering gear casings.
• Requirements: Lightweight (aluminum parts reduce vehicle weight by 10–15%), high strength (tensile strength ≥280MPa), and corrosion resistance.
• Example: A factory might produce 1 million aluminum battery frames annually for a major EV manufacturer, meeting IP68 waterproof standards.

B. Consumer Electronics (20–25% of Revenue)

• Products: Mobile phone middle frames, laptop hinges, wireless headphone charging compartments, LED heat sinks.
• Requirements: Precision (tolerance ±0.05mm), small size (10–500g), and good surface finish (anodized or plated).
• Example: Supplies zinc alloy charging port housings to a smartphone brand—100,000 units/week with zero surface defects.

C. Household Appliances (10–15% of Revenue)

• Products: Air conditioning compressor housings, washing machine drum bearing seats, refrigerator door hinges.
• Requirements: Tightness (no water leakage), impact resistance, and low cost.
• Example: Produces aluminum compressor housings for a home appliance company—parts pass 10,000-cycle vibration tests.

D. Communication Equipment (5–10% of Revenue)

• Products: 5G base station cooling modules, router shells, fiber optic connector housings.
• Requirements: Heat dissipation (high thermal conductivity), electromagnetic shielding, and weather resistance.
• Example: Manufactures magnesium alloy cooling modules for 5G towers—parts withstand -40°C to +85°C temperature ranges.

E. Medical Devices (3–5% of Revenue)

• Products: CT machine rotating frames, surgical instrument handles, insulin pump casings.
• Requirements: Biocompatibility (ISO 10993), high precision (±0.03mm), and easy sterilization.
• Example: Supplies titanium-aluminum alloy surgical tool handles to a medical device firm—parts pass autoclave sterilization (134°C, 20 minutes) 1,000+ times.

4. How Die Casting Factories Compare to Other Manufacturing Processes

Die casting factories differ from sand casting, stamping, and injection molding facilities in key ways. The table below highlights critical differences:

5. Yigu Technology’s Perspective on Die Casting Factories

At Yigu Technology, we believe die casting factories are the backbone of modern manufacturing—bridging raw metal and high-performance end products. Our factory integrates 3 core strengths: 1) AI-driven process control (real-time adjustment of injection speed/pressure reduces defect rates to <1.5%); 2) Green manufacturing (vacuum die casting cuts energy use by 20%, and 95% of scrap is recycled); 3) Cross-process integration (die casting + CNC machining + surface treatment on one line shortens lead time by 40%).

For automotive clients, we produce 500,000+ aluminum battery frames yearly with IP68 certification. For electronics clients, our zinc alloy parts meet ±0.05mm precision. We’re investing in 3D-printed mold technology to cut NPD time to 3 weeks. Our goal is to be more than a supplier—we’re a partner that helps clients optimize designs for cost, quality, and sustainability.

FAQ

1. What is the minimum order quantity (MOQ) for a die casting factory?

MOQ depends on mold costs: For standard parts (e.g., generic brackets), MOQ is 10,000–50,000 units to offset mold expenses. For custom parts, we offer flexible MOQ (1,000–5,000 units) using shared molds, though per-part costs are slightly higher.

2. How long does it take for a die casting factory to deliver a custom order?

For new custom parts: 4–8 weeks (includes 3–4 weeks for mold design/manufacturing, 1–2 weeks for sampling, and 1–2 weeks for mass production). For repeat orders: 1–2 weeks (no mold lead time).

3. Can a die casting factory handle post-processing like CNC machining?

Yes—most die casting factories (including Yigu Technology) integrate CNC machining into their workflow. This is critical for parts that need ultra-precise features (e.g., threaded holes with ±0.02mm tolerance) that can’t be achieved via die casting alone. We use 5-axis CNC machines to ensure accuracy and efficiency.