High Pressure Die Casting Services for Reliable Mass Production

High Pressure Die Casting is one of the most efficient ways to produce consistent, high-strength metal parts at scale. At XY-GLOBAL, we support aluminum and zinc alloy high pressure die casting with complete tooling, production, CNC machining, and quality inspection.

This page gives you a clear, practical overview of the high pressure die casting process, its advantages, and the industries we serve.

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1. What is High Pressure Die Casting?

High Pressure Die Casting is a manufacturing process that injects molten metal into a steel mold using high speed and high pressure.
The result is a dense, precise part suitable for large-volume production.

Because of its ability to form thin walls, complex shapes, and stable dimensions, high pressure die casting is widely used in automotive, robotics, industrial equipment, and consumer electronics.

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2. High Pressure Die Casting Production Steps

Our high pressure die casting production follows a controlled and standardized workflow to ensure repeatable quality.

1) Mold Design & Tooling

• Detailed DFM review

• Gate, runner, and overflow design

• Cooling channel layout

• Steel material: H13 / SKD61
  High pressure die casting quality begins with a reliable mold.

2) Metal Melting

Aluminum or zinc alloy is melted at a controlled temperature to ensure stable fluidity and prevent defects.

3) High-Pressure Injection

Metal is injected into the mold at:

• Speed up to 30–80 m/s

• Pressure 50–120 MPa
  This step defines the accuracy and density of high pressure die casting parts.

4) Cooling & Ejection

The part solidifies inside the mold and is then ejected automatically. Proper cooling design ensures uniform wall thickness and reduces warpage.

5) Trimming & CNC Machining

After casting:

• Gates and flash are removed

• CNC machining is applied to critical surfaces

• Surface finishing is done as needed

6) Quality Inspection

We apply:

• CMM dimensional checking

• X-ray for internal porosity

• Leak testing for sealing parts

• Hardness and material verification

Every batch of high pressure die casting parts goes through this process to maintain consistency.

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3. Advantages of High Pressure Die Casting

High Pressure Die Casting provides several clear benefits for mass production projects:

✔ High dimensional consistency

Parts remain stable across large quantities, suitable for assemblies and tight-fit components.

✔ Ideal for complex geometries

Thin walls, ribs, deep cavities, and detailed structures can all be achieved with high pressure die casting.

✔ Smooth surface finish

The steel mold produces cleaner surfaces and reduces the amount of machining required.

✔ Strong mechanical properties

The dense material structure enhances strength and reduces internal defects.

✔ Cost-effective for medium to high volumes

Once tooling is set, high pressure die casting offers a lower cost per piece for large orders.

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4. Materials for High Pressure Die Casting

We support the most commonly used alloys:

Aluminum Alloy

• Lightweight

• Strong mechanical performance

• Good corrosion resistance

The most popular choice for high pressure die casting in automotive and robotics.

Zinc Alloy

• Excellent fluidity

• High dimensional accuracy

• Suitable for small and intricate parts

Magnesium (on request)

• Ultra-lightweight

• Good for electronics and portable devices

5. Applications of High Pressure Die Casting

High pressure die casting is used in many industries that require stable, repeatable production.

Automotive Components

• Motor housings

• Brackets

• Transmission parts

• Heat dissipation structures

Robotics & Industrial Automation

• Joint housings

• Structural supports

• Gearbox covers

AGV & AMR Components (fits your XY-GLOBAL AGV business)

• Motor housing

• Lifting system parts

• Steering unit shells

• Lightweight frame structures

Consumer Electronics

• Thin-wall covers

• Magnesium housings

• Heat-sink components

Medical & Laboratory Equipment

• Device enclosures

• Precision brackets

• Lightweight structural pieces

High pressure die casting supports stable mass production across all these fields.

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6. High Pressure Die Casting vs Other Processes

For products above 2,000 pcs, high pressure die casting is often the best balance of quality and cost.

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7. Why Choose XY-GLOBAL for High Pressure Die Casting?

✔ Strong tooling and DFM capability

We optimize mold design before production to reduce defects such as porosity and warpage.

✔ Full production line

• 160T–1250T die casting machines

• Automatic spraying and robotic extraction

• In-house CNC machining centers

✔ One-stop manufacturing

From high pressure die casting → machining → finishing → assembly → packaging.

✔ Strict quality control

• X-Ray

• CMM

• Leak testing

• Full traceability

✔ Global service capability

Serving customers in the US, Europe, Japan, Korea, Australia, and Southeast Asia.

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8. Start Your High Pressure Die Casting Project

Whether you need prototypes, DFM support, or mass production, XY-GLOBAL provides stable and cost-effective high pressure die casting solutions.

Contact us today to discuss your drawings, tolerance requirements, materials, and expected production quantity.

High Pressure Die Casting FAQ

1. What is High Pressure Die Casting used for?

High Pressure Die Casting is mainly used for aluminum and zinc alloy parts that require stable dimensions, thin walls, and mass-production capability. Common applications include motor housings, brackets, gearbox covers, AGV components, and electronic enclosures.

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2. What materials can be used in High Pressure Die Casting?

The most commonly used materials are:

• Aluminum alloys (such as ADC12, A380)

• Zinc alloys (such as Zamak 3, Zamak 5)

• Magnesium alloys (optional)
  Different alloys provide different levels of strength, weight, and dimensional stability.

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3. What are the main advantages of High Pressure Die Casting?

• Excellent dimensional consistency

• Good surface finish

• Suitable for complex structures and thin walls

• High production efficiency

• Cost-effective for medium to high volumes
  These features make high pressure die casting ideal for industrial and automotive components.

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4. What tolerance can be achieved with High Pressure Die Casting?

Typical tolerances are ±0.05 mm to ±0.10 mm, depending on part size and structure.
Critical features can be finished through CNC machining for higher precision.

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5. Does High Pressure Die Casting require post-machining?

Yes, many parts need CNC machining for:

• Hole accuracy

• Flatness

• Threads

• Assembly interfaces
  XY-GLOBAL provides full die casting + CNC one-stop service.