Die Casting Australia
Aluminium, zinc, and magnesium die casting sourced through Rapid Manufacturing's audited supplier network. High pressure, low pressure, and gravity die casting. Post-machining integration available. Quotes within 2 business days.
Die Casting Processes
High Pressure Die Casting
Molten metal injected at 10–175 MPa into a steel die. Fast cycle times (seconds to minutes), excellent dimensional consistency, and complex geometry capability. The most common die casting process for aluminium and zinc.
- ✓ Injection pressure to 175 MPa
- ✓ Fast cycle times
- ✓ Thin walls to 1.0mm
- ✓ High volume efficiency
Low Pressure Die Casting
Die filled slowly under low pressure (0.02–0.1 MPa) from a pressurised furnace below. Less turbulence means reduced porosity — critical for structural parts, pressure-tight components, and parts requiring heat treatment.
- ✓ Reduced porosity
- ✓ Better mechanical properties
- ✓ Pressure-tight castings
- ✓ Aluminium wheels and structural parts
Gravity Die Casting
Molten metal poured into a permanent steel mould by gravity. No external pressure. Produces denser castings than sand casting at lower tooling cost than high pressure dies. Suited to medium volumes and larger components.
- ✓ Lower tooling cost
- ✓ Denser than sand casting
- ✓ Medium volumes
- ✓ Larger component sizes
Die Casting Materials
Aluminium is the most commonly die cast metal in Australia. Zinc and magnesium are used for specialist applications.
Aluminium Die Casting
Alloys: A380, A383, A360, ADC12, 356, A357
Lightweight, good strength, excellent heat dissipation, corrosion resistant, paintable
Electronics housings, automotive parts, industrial equipment, structural components
Zinc Die Casting (Zamak)
Alloys: Zamak 2, Zamak 3 (most common), Zamak 5, ZA-8
Excellent fluidity for thin walls, high accuracy, self-lubricating, good surface finish
Connectors, handles, decorative hardware, intricate thin-wall components
Magnesium Die Casting
Alloys: AZ91D (most common), AM60, AM50
Lightest structural metal, excellent strength-to-weight, good EMI shielding
Automotive components, electronics enclosures, aerospace where weight is critical
Why Die Casting?
High Volume Efficiency
Die casting has the lowest part cost of any near-net-shape metal process at volume. Once the die is amortised, cycle times of 30–120 seconds produce thousands of consistent parts per day.
Complex Geometry
Internal channels, undercuts, thin walls (to 1.0mm in aluminium), integrated bosses, ribs, and holes are all achievable in a single casting. Reduces or eliminates assembly operations.
Tight As-Cast Tolerances
High pressure die casting achieves ±0.1–0.2mm on most features — better than sand casting. Combined with CNC post-machining, critical features can hold ±0.01mm.
Excellent Surface Finish
Die-cast surfaces are smooth (Ra 1.6–3.2μm as-cast), ready for painting, powder coating, anodising, or plating without extensive preparation.
Material Utilisation
Near-net-shape process — minimal material waste compared to machined components. Runner systems and sprues are recycled back into the furnace.
Integrated Post-Machining
Rapid Manufacturing coordinates die casting with secondary CNC machining, ensuring critical bores, threads, and sealing faces meet your engineering requirements in a single supply chain.
Die Casting FAQ
What is die casting?
Die casting is a manufacturing process in which molten metal is injected under high pressure into a precision steel mould (die). The metal solidifies rapidly, ejected from the die, and the cycle repeats. Die casting produces near-net-shape components with excellent dimensional consistency, smooth surface finishes, and complex geometry — including undercuts, thin walls, and integrated features like bosses, ribs, and holes. It is highly cost-effective for medium to high production volumes once the die tooling cost is amortised.
What is the difference between high pressure and low pressure die casting?
High pressure die casting (HPDC) injects molten metal at 10–175 MPa. Cycle times are fast (seconds to minutes), producing dense, consistent parts ideal for automotive components, housings, and consumer products. Low pressure die casting (LPDC) fills the die slowly at 0.02–0.1 MPa by pressurising the furnace. This produces less turbulence, reducing porosity — important for structural aluminium castings requiring pressure-tightness, such as automotive wheels, cylinder heads, and structural housings. Gravity die casting (GDC) uses no external pressure and is best for simple shapes in medium volumes.
What aluminium alloys are used in die casting?
The most common die casting aluminium alloys are A380 (most widely used — excellent castability, good strength and corrosion resistance), A383 (A380 variant with better die filling for complex thin-wall parts), A360 (higher corrosion resistance, good ductility), and ADC12 (popular in Asia-Pacific, similar to A383). For structural applications requiring higher strength, 356 and A357 are used in low-pressure die casting with T6 heat treatment. Alloy selection depends on mechanical requirements, corrosion environment, secondary machining, and surface finishing requirements.
What tolerances can die casting achieve?
High pressure die casting achieves dimensional tolerances of ±0.1–0.2mm on as-cast features for small to medium parts. Critical features (bores, datum faces, mating surfaces) require secondary CNC machining to achieve ±0.01–0.05mm tolerances. Wall thicknesses of 1.0–1.5mm are achievable in aluminium die casting. Surface finish on die-cast faces is typically Ra 1.6–3.2μm as-cast, suitable for direct painting or powder coating. Tighter tolerances, smoother finishes, and threaded holes require post-machining operations.
How much does die casting tooling cost in Australia?
Die casting tooling (the steel die/mould) is the primary upfront cost. Simple single-cavity dies for small parts: AUD $5,000–$20,000. Medium complexity multi-cavity dies: AUD $20,000–$80,000. Large complex dies for automotive or industrial components: AUD $80,000–$300,000+. Die life is typically 100,000–1,000,000 shots for aluminium. The tooling cost is amortised over the production run — at high volumes, die casting is the lowest cost per piece of any near-net-shape process. Rapid Manufacturing helps you evaluate tooling ROI based on your expected volumes and component requirements.
What industries use die casting in Australia?
Die casting is used across automotive (engine housings, transmission cases, brackets), electronics (heat sinks, enclosures, connector housings), telecommunications (base station components, antenna housings), industrial equipment (pump bodies, valve bodies, gearbox covers), consumer products (power tool housings, appliance components), and defence (lightweight structural components, communication equipment enclosures). Aluminium die casting is used where light weight, heat dissipation, or corrosion resistance are priorities. Zinc die casting is chosen for intricate thin-wall components, decorative parts, and connectors.
Can die castings be CNC machined after casting?
Yes — post-machining of die castings is standard practice. As-cast tolerances (±0.1–0.2mm) are sufficient for non-critical faces, mounting bosses, and general form. Critical bores, precision holes, threaded features, and tight-tolerance mating surfaces are machined after casting. Rapid Manufacturing coordinates the complete supply chain — from die casting through to secondary CNC machining, surface finishing, and assembly — through its audited supplier network. This integrated approach ensures quality control across the entire manufacturing process.
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