Die casting processing cost refers to the total expense of manufacturing die cast parts, covering material procurement, equipment operation, mold use, labor, and post-processing. It varies widely—for example, aluminum alloy parts processed by a 200-ton machine may cost ~\(0.45/kg, while complex copper alloy parts with high-precision requirements can exceed \)5/kg. This huge gap stems from multiple interrelated factors. But what exactly makes up the cost? How do different factors affect the final price? And how can you get an accurate quotation to control costs? This article answers these questions with detailed data and practical guidance.
1. Breakdown of Die Casting Processing Cost: Core Components
Die casting processing cost is not a single figure—it consists of 5 mutually influencing components. The table below details each part, its proportion, and calculation basis:
| Cost Component | Typical Proportion (Total Cost) | Calculation Method & Key Details | Industry Benchmarks (Aluminum Alloys) |
| Material Cost | 50–60% | (Raw material price + waste loss rate × raw material price) × part weight- Waste loss rate: 8–15% (depends on process; higher for complex parts) | Raw aluminum price: \(2.5–\)3/kg; total material cost per kg part: \(2.7–\)3.45 |
| Equipment Operation Cost | 15–20% | (Machine hourly energy consumption × electricity price + machine depreciation) ÷ hourly output- Machine depreciation: Calculated over 8–10 years (200-ton machine: ~$80,000 initial cost) | 200-ton machine: \(0.15–\)0.2/kg; 300-ton machine: \(0.25–\)0.35/kg |
| Mold Cost | 5–10% | (Mold manufacturing cost + maintenance cost) ÷ total production quantity- Mold life: 50,000–100,000 shots (aluminum alloy molds) | Simple mold: \(5,000–\)10,000; complex mold (with sliders): \(20,000–\)50,000 |
| Labor Cost | 8–12% | (Number of workers × hourly wage) ÷ hourly output- Automation level affects labor needs: Fully automated lines need 1–2 workers/line; semi-automated need 3–5 | Hourly wage: \(15–\)25; labor cost per kg part: \(0.12–\)0.3 |
| Post-Processing Cost | 5–15% | Cost of cutting, sandblasting, plating, or heat treatment- Complexity drives cost: Simple deburring is cheap; precision CNC machining is expensive | Deburring: \(0.05–\)0.1/kg; sandblasting + plating: \(0.5–\)1.2/kg |
2. Key Pricing Models for Die Casting Processing
Manufacturers use 2 main pricing models to calculate costs—each suitable for different scenarios. The table below compares their pros, cons, and ideal use cases:
| Pricing Model | Calculation Formula | Advantages | Disadvantages | Ideal For |
| Equipment Tonnage-Based Pricing | Cost per kg = Base rate (per tonnage) + material premium (if using non-aluminum alloys)- Example: 200-ton machine: \(0.45/kg; 300-ton machine: \)0.65/kg | Simple, fast calculation; easy for customers to understand | Ignores part complexity; may overcharge for simple parts | Large-batch, simple parts (e.g., automotive brackets, basic hardware) |
| Itemized Costing (Precision Quotation) | Total cost = Material cost + equipment cost + mold cost + labor cost + post-processing cost + profit margin (10–15%) | Accurate; reflects part-specific requirements; fair for both parties | Time-consuming; requires detailed part information (drawings, materials) | Complex, high-precision parts (e.g., medical device components, aerospace parts) |
3. Core Factors Influencing Die Casting Processing Cost
Multiple factors cause cost fluctuations—some can increase expenses by 30% or more. Below is a detailed analysis of 6 key factors with quantitative impacts:
A. Material Type (Biggest Cost Driver)
Different metals have vastly different prices and process requirements:
- Aluminum Alloys: Lowest cost (\(2.7–\)3.45/kg material cost); easy to process; ideal for most general parts.
- Zinc Alloys: Slightly higher cost (\(3.5–\)4.2/kg material cost); good for small, precise parts (e.g., electronics housings).
- Copper Alloys: High cost (\(8–\)10/kg material cost); requires higher temperature and pressure; used for heat-conducting parts (e.g., heat sinks).
- Magnesium Alloys: Premium cost (\(6–\)7.5/kg material cost); lightweight but requires strict safety measures (flammable); used in aerospace/automotive lightweight parts.
B. Part Complexity & Design
Complex designs increase mold, labor, and post-processing costs:
- Structural Complexity: Parts with sliders, hydraulic core pulling, or insert installation add 20–50% to mold cost. For example, a part with 2 sliders costs 30% more than a simple part of the same weight.
- Wall Thickness: Uneven wall thickness (ratio >3:1) reduces production efficiency by 15–25% (more rework needed), increasing labor and equipment costs.
- Precision Requirements: Tolerances tighter than ±0.1mm require precision machining, adding \(0.3–\)0.8/kg to post-processing cost.
C. Order Volume (Critical for Cost Reduction)
Larger batches lower unit costs due to economies of scale:
- Small Batches (<10,000 parts): High unit cost—mold cost is spread over fewer parts. For example, a \(10,000 mold for 5,000 parts adds \)2/part to the cost.
- Medium Batches (10,000–50,000 parts): Balanced cost—mold and equipment costs are spread reasonably; manufacturers may offer 5–10% discounts.
- Large Batches (>50,000 parts): Lowest unit cost—automation is feasible, labor costs drop, and material suppliers offer volume discounts (5–15% off raw material prices).
D. Mold Condition & Maintenance
Poor mold condition increases rework and scrap rates, driving up costs:
- New Molds: Low scrap rate (<2%); no extra maintenance cost in the first 10,000 shots.
- Worn Molds: Scrap rate rises to 5–8%; require monthly maintenance (\(200–\)500/mold) to fix gaps or surface damage.
- Customer-Supplied Molds: If the mold needs debugging (e.g., adjusting core position) or overhaul (e.g., replacing worn components), additional costs of \(500–\)2,000 may apply.
E. Post-Processing Requirements
Additional operations significantly increase costs—each step adds 5–15% to the total:
| Post-Processing Step | Cost Impact (Per kg Part) | Purpose |
| Deburring (manual) | \(0.05–\)0.1 | Remove sharp edges |
| CNC Machining | \(0.8–\)2 | Achieve high precision (±0.05mm) |
| Sandblasting | \(0.2–\)0.4 | Improve surface roughness (Ra <1.6μm) |
| Plating (chrome/nickel) | \(0.8–\)1.5 | Enhance corrosion resistance and aesthetics |
| Heat Treatment (T6) | \(0.3–\)0.6 | Increase tensile strength (from 200MPa to 300MPa+) |
F. Regional Cost Differences
Labor, electricity, and rent vary by region, affecting overall costs:
- North America/Europe: High costs—electricity (\(0.15–\)0.25/kWh), labor (\(15–\)25/hour); total cost per kg part: \(4–\)6.
- Asia (China, Vietnam): Lower costs—electricity (\(0.05–\)0.1/kWh), labor (\(5–\)10/hour); total cost per kg part: \(2–\)4.
- South America: Medium costs—electricity (\(0.1–\)0.15/kWh), labor (\(8–\)12/hour); total cost per kg part: \(3–\)5.
4. Practical Guide: How to Get an Accurate Quotation & Control Costs
To avoid overpaying and ensure cost transparency, follow these 4 steps:
Step 1: Prepare Detailed Information for Manufacturers
Provide 3 key pieces of data to get a precise quote:
- 2D/3D Drawings: Include dimensions, tolerances (e.g., ±0.1mm), and structural details (e.g., number of sliders).
- Material Specifications: Clarify alloy type (e.g., A380 aluminum, ZAMAK 5 zinc) and quality standards (e.g., ASTM, ISO).
- Order Details: Annual purchase volume, delivery schedule, and post-processing requirements (e.g., “need sandblasting + T6 heat treatment”).
Step 2: Compare Quotations Smartly
Don’t just choose the cheapest—evaluate 5 factors:
- Cost Breakdown: Ask for a detailed breakdown (material, equipment, mold, etc.) to check for hidden fees.
- Equipment Capabilities: Ensure the manufacturer has machines matching your part’s needs (e.g., 300-ton machine for large parts).
- Quality Certifications: Look for ISO 9001 (quality) or IATF 16949 (automotive) to avoid rework costs from poor quality.
- Lead Time: Longer lead times may mean higher inventory costs; choose manufacturers with 2–4 week lead times for standard parts.
- After-Sales Service: Check if they offer mold maintenance or defect replacement—this reduces long-term costs.
Step 3: Negotiate for Cost Savings
Use these 3 strategies to lower costs without compromising quality:
- Volume Commitments: Promise annual volumes >50,000 parts to get 10–15% discounts on unit costs.
- Long-Term Partnerships: Sign 1–2 year contracts for stable pricing (avoids raw material price fluctuations).
- Design Optimization: Work with the manufacturer to simplify designs (e.g., reduce sliders, balance wall thickness) to cut mold and process costs by 15–20%.
Step 4: Monitor Costs During Production
Track 3 key metrics to avoid cost overruns:
- Scrap Rate: Keep it <3% (industry average); higher rates mean wasted materials and labor.
- Mold Maintenance Frequency: Schedule maintenance every 10,000 shots to prevent unexpected downtime (costs \(500–\)2,000/hour).
- Material Waste: Optimize part nesting (arrange multiple parts in one mold) to reduce waste loss rate from 15% to 8–10%.
5. Yigu Technology’s Perspective on Die Casting Processing Cost
At Yigu Technology, we believe cost control in die casting is about balancing precision, quality, and efficiency—not just cutting expenses. For automotive clients, our itemized costing model (with 100% transparent breakdowns) and design optimization services reduced their total costs by 18%. For medical device manufacturers, we use shared molds (for small batches) to lower mold cost per part by 40%, while maintaining ISO 13485 quality standards.
We’re advancing two cost-saving innovations: 1) AI-driven process optimization (reduces scrap rate to <2% and energy consumption by 12%); 2) Modular mold design (allows mold components to be reused across parts, cutting mold cost by 25%). Our goal is to help clients get high-quality die cast parts at competitive prices—turning cost control into a competitive advantage.
FAQ
- Why does the same part have different quotes from different manufacturers?
Quotes vary due to 4 factors: 1) Equipment efficiency (newer machines have lower operation costs); 2) Regional labor/electricity prices; 3) Quality standards (ISO-certified manufacturers charge more for better quality); 4) Mold reuse (manufacturers with existing similar molds offer lower quotes). Always ask for a cost breakdown to compare apples to apples.
- How much does mold cost affect the unit price of small-batch parts?
For small batches (<10,000 parts), mold cost is a major factor. For example, a \(10,000 mold for 5,000 parts adds \)2/part to the unit cost—this can double the total price. To reduce this impact, ask about shared molds (split mold cost with other clients) or short-life molds (cheaper, for <5,000 shots).
- Can post-processing be skipped to save costs?
It depends on the part’s use: 1) Non-visible, non-load-bearing parts (e.g., internal brackets) can skip sandblasting/plating (saves \(0.5–\)1.2/kg); 2) Visible parts (e.g., consumer electronics housings) need surface treatment to avoid aesthetics issues; 3) Load-bearing parts (e.g., automotive structural parts) require heat treatment (cannot skip—this ensures strength and safety). Skipping necessary post-processing leads to higher defect rates and long-term costs.