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Aluminum Die Casting and Die Cast Metal Products

Die casting is a metal casting process that involves forcing molten metal under high pressure into a mold cavity to produce cast metal parts. The most common metal used in die casting is aluminum due to its excellent castability, high strength-to-weight ratio, good corrosion resistance, electrical conductivity, and ability to be recycled. Aluminum die casting is widely used across various industries such as automotive, aerospace, consumer products, industrial machinery, medical devices, and more.

The Die Casting Process

The aluminum die casting process involves melting aluminum ingots and forcing the molten aluminum at high velocity and under pressure into steel molds called dies. The dies are created with a cavity that forms the desired part shape. The high pressure injection of the molten aluminum allows the metal to completely fill the die and produce the part in precise detail.

Once the molten aluminum solidifies in the die, the die opens and automatically ejects the new cast part. The part may require some additional finishing work such as polishing or surface treatments, but the die casting process produces near net-shape parts that require minimal secondary machining. This makes die casting one of the most efficient and economical metal shaping processes available.

Benefits of Aluminum Die Casting

There are several key benefits that make aluminum die casting one of the most popular manufacturing processes today:

- Excellent dimensional accuracy and repeatability for high volumes of complex parts
- Smooth cast surfaces and precise details from the hardened tool steel dies
- High production rates and low labor costs due to automation
- Low scrap losses since molten metal is fully injected into the die
- Ability to cast intricate shapes with walls as thin as 1mm or less
- Wide range of alloy options including high strength and corrosion resistant alloys
- Lightweight aluminum parts compared to steel or iron
- Parts can be cast with textured surfaces or plated/painted in a variety of finishes

Common Aluminum Die Cast Parts

Aluminum die casting produces durable and stable parts that are ideal for a wide range of applications across many industries. Some of the most common aluminum die cast parts include:

Automotive - Engine blocks, transmission cases, wheel spacers, control arms, steering knuckles, cylinder heads, car wheels
Aerospace - Aircraft fittings, hydraulic manifolds, electronic housings, landed gear components
Consumer products - Power tool housings, appliances, outdoor lighting, recreational products
Industrial - Pump housings, machine bases, motor mounts, valve bodies, fork lift parts
Medical - MRI housings, surgical clamps, medical instruments, prosthetics
Electronics - Heatsinks, computer housings, telecom equipment, lighting fixtures

Popular Aluminum Alloys Used in Die Casting

The aluminum alloy used for a particular die cast part is selected based on the mechanical and physical properties required by the part's application and design. Some of the most widely used aluminum alloys in die casting include:

380 Alloy - The most popular; offers excellent castability and corrosion resistance. Used for housings, covers, cylinders, and vehicle parts.

383 Alloy - Similar to 380 but with slightly higher strength. Used for housings, sleeves, and cylinder heads.

360 Alloy - Good castability with high ductility and impact strength. Used for parts that require machining.

319 Alloy - Excellent castability with better strength properties than 380 or 383. Used for automotive parts.

336 Alloy - The strongest die cast alloy with ultimate tensile strength of 48,000 psi. Used for parts requiring high strength.

355 Alloy - Highest ductility of all die cast alloys. Used for parts requiring impact strength.

413 Alloy - Excellent corrosion resistance. Used for outdoor lighting fixtures and marine products.

390 Alloy - Excellent heat resistance alloy. Used for parts exposed to high operating temps.

Choosing an Aluminum Die Casting Company

When sourcing an aluminum die casting company, it’s important to consider the company's capabilities, experience, quality processes, and services. Key factors to evaluate include:

- Experience with the specific type of aluminum parts you require
- Available aluminum die casting alloys and sizes
- Die casting facilities and production capacity
- Advanced die casting machines (hot or cold chamber)
- Design engineering and simulation capabilities
- Finishing and secondary machining services
- Quality certifications such as ISO 9001
- Use of quality inspection and testing procedures
- Experience with automotive, aerospace, or medical manufacturing
- Rapid prototyping abilities for concept parts
- Location, costs, and ease of working relationship

Leading aluminum die casting companies will provide complete services from design and prototyping through production and finishing. They will also apply quality processes to ensure your die cast parts meet specifications throughout the production run. Partnering with an experienced and capable die casting company provides significant benefits in quality, costs, and delivery for your aluminum die cast parts.


Aluminum die casting produces precise, complex metal parts at high volumes with low unit costs. It is a proven manufacturing process to economically produce lightweight, durable aluminum components for diverse industries. With a range of aluminum alloys and the latest die casting technologies, today's aluminum die casting companies can deliver high quality, tight tolerance die cast parts using efficient and repeatable techniques. By selecting an experienced partner, manufacturers can leverage the many benefits of aluminum die casting while upholding the highest standards for part design, production quality, costs, and on-time delivery. CNC Milling CNC Machining