General Die Casters FAQs

We make custom aluminum parts using high-pressure die casting. We also provide engineering support, tooling evaluation, CNC machining, finishing, and assembly as value-added services related to our core die casting manufacturing process.

We supply aluminum die castings for heavy truck, lawn and garden, energy, building and construction, lighting, automotive, appliances and home goods, recreational, electronics, industrial, and medical applications.

Send a 3D CAD model, a dimensioned drawing, your proposed alloy, expected annual volume, and program life. Mark critical tolerances, cosmetic surfaces, and machined features. Include any leak-testing or pressure-tightness requirements.

Part size, geometry, cavity count, slides, and tolerance requirements all affect the initial tooling price. When comparing options, also account for maintenance, replacement cavities, and the cost of sampling and approving replacements.

A die with more cavities can lower the cost per part at higher volumes, but it costs more upfront and may require a larger machine. For complex or lower-volume parts, fewer cavities may cost less over the life of the program.

We typically make parts with volumes of 10,000-150,000/year. We do accommodate volumes both greater and less than based on the part requirements and the overall business package.

We cast aluminum alloys including 360, 380, 383, B390, and 413. Alloy selection depends on the part’s application, performance requirements, and cost.

We can review your application and recommend an alloy. Let us know if the part needs wear resistance, corrosion resistance, or pressure tightness.

We review new and existing part designs to identify casting, machining, or tooling issues. Catching a problem on a drawing is usually less expensive than correcting it after the die has been built.

We use MAGMASOFT to model how aluminum fills and solidifies in the die. Our engineers use the results to evaluate runners, vents, and cooling before building or modifying tooling.

Keep wall thickness consistent, allow enough draft, and use rounded corners. Avoid unnecessary undercuts and complicated parting lines. Features that leave thin steel sections in the die can wear quickly and increase maintenance costs.

Draft is a slight taper that helps the part release from the die. Without enough draft, the casting can drag or distort during removal. The amount of draft needed depends on feature depth, alloy, and whether the surface is inside or outside the part.

Tolerances depend on the feature, part geometry, and location in the die. Dimensions that cross the parting line are harder to control than those contained in one die half. We review your drawing to determine which tolerances we can hold through casting and which require machining.

Typically, yes. Before accepting a tool transfer, we inspect the die, check that it fits our equipment, and assess whether it can meet your part requirements. Repairs or modifications may be needed, but you may be able to keep using your existing tooling.

Send models of the die and runner system, the machine size previously used, recent dimensional reports, and any available process data. We also need your production schedule, inventory levels, and critical part requirements to plan the move.

Build safety stock if you can. The die will be out of production during shipping, evaluation, sampling, and approval. Extra inventory helps cover that downtime.

We inspect the tooling, review the process, and determine whether repairs or changes are needed. We then sample parts and verify that they meet requirements. Depending on the program, approval can include dimensional layouts, capability studies, and the Production Part Approval Process.

Our in-house tool room repairs and modifies production tooling. We clean and inspect dies, track their usage, and use that information to plan maintenance and replacements.

Lead times are project dependent. Die cast tooling lead times will vary, but are typically in the 12-20 week range, depending on the size and complexity of the tooling. Casting lead time is usually 6-8 weeks. If other operations are involved, that lead time can be extended a little longer. In most situations, we can hit our customer’s forecast. With a forecast and blanket purchase order, we can provide the parts wherever our customer needs them.

Blanket orders, with forecasts and scheduled releases, are the recommended format for ordering die castings.

We are ISO 9001:2015 certified. Our quality management system covers how we control, monitor, and improve our processes to meet customer requirements.

We use coordinate measuring machines and a 3D scanner for dimensional inspection, real-time X-ray to examine internal defects, and a spectrometer to check alloy chemistry.

We use Shotscope and Visi-Trak process monitors, monitor casting conditions, control die temperatures, maintain equipment, and inspect parts during production. These checks help us catch changes that could affect part quality.

We produce castings for pressure-tight applications and offer leak testing. Pressure tightness depends on the alloy, part design, casting conditions, and machining. When needed, we can arrange impregnation to seal leak paths in suitable parts. We also utilize vacuum assisted casting technology to achieve maximum integrity.

You can’t eliminate porosity completely, but you can control it. Part and die design, venting, cooling, and casting pressure help limit porosity and keep it away from critical areas.

X-ray inspection lets us examine internal porosity that is not visible on the surface. For pressure-tight parts, leak testing checks whether connected pores create a leak path.

Machining can cut through the casting’s dense outer skin and expose pores underneath. Tell us which surfaces will be machined during the design review so we can account for them in the runner, venting, and cooling design.

Our in-house CNC capabilities include turning, milling, and four- and five-axis machining. We machine features that cannot be cast directly or need tighter tolerances than casting alone can hold.

We perform shot blasting, spin and tumble blasting, sanding, and heat treating in-house. We also manage outside services such as painting, anodizing, vibratory deburring, and impregnation.

We offer assembly, roll forming, and kitting. Past work includes assembling castings with customer-supplied components and packaging multiple parts together.