When buyers look for precision aluminum parts with reliable consistency and sharp detail, high pressure die casting (HPDC) often becomes the go-to method. As a factory with over 20 years in aluminum die casting, we use HPDC for most of our production—especially for parts used in automotive, medical, and industrial machinery sectors.
Let us walk you through what high pressure die casting actually means, why we use it, and how it compares with other options.
What Does “High Pressure” Really Mean in Die Casting?
In high pressure die casting, molten aluminum is injected into a steel mold at forces ranging from 1000 to 2000 bar. That’s over 2000 times atmospheric pressure. This pressure allows the molten metal to quickly fill intricate mold cavities before it solidifies, resulting in parts with high precision and excellent surface finish.
This is very different from gravity casting or low-pressure casting, where the metal flows more slowly and with less force. HPDC enables us to achieve thinner walls, sharper edges, and finer details. The entire cycle typically completes in 30 to 90 seconds, making it ideal for high-volume orders.
What Are the Key Steps in High Pressure Die Casting?
The high pressure die casting process involves several tightly controlled steps. Although every mold is different, this is the basic sequence we follow at our factory:
- Melting aluminum alloy (usually ADC12) in the holding furnace.
- Injecting the molten alloy into the die using high pressure.
- Solidifying the aluminum inside the mold cavity.
- Opening the mold and ejecting the finished part.
- Trimming and cleaning the part to remove gates and flash.
Here’s a quick look at the parameters we typically control in this process:
| Parameter | Value Range |
|---|---|
| Pressure | 1000–2000 bar |
| Mold Temp | 180–300°C |
| Injection Speed | 1–6 m/s |
| Alloy Temp | ~660–690°C (ADC12) |
| Tolerance Range | ±0.05 mm to ±0.10 mm |
All of these variables depend on the part size, wall thickness, and alloy used.
Why We Use High Pressure Die Casting for Most Aluminum Parts
More than 80% of the aluminum die casting orders we handle involve high pressure die casting. It gives us better results on complex shapes, especially when the parts require tight tolerances or thin walls.
Some of the most common components we manufacture using HPDC include:
- Electronic control housings for EVs
- Medical device enclosures
- Power tool casings
- Industrial pump bodies
In our experience, HPDC delivers both mechanical strength and visual quality, with very little need for rework.
What Makes HPDC More Efficient Than Other Methods?
One of the main advantages of HPDC is its speed. Because the injection and solidification cycles are short, we can produce large quantities quickly. In fact, a single cavity can deliver up to 100 parts per hour in some cases.
This speed doesn’t come at the cost of quality. The process allows for:
- Fewer porosity issues (when gate and venting are optimized)
- Good repeatability over thousands of cycles
- Smooth surface finish, often requiring no machining
Here’s how high pressure die casting increases efficiency:
Key Efficiency Gains:
- Cycle time: ~60 seconds per shot
- Scrap rate: typically below 3% with proper setup
- Multi-cavity molds improve output
- Steel dies can run for 50,000–100,000 shots before repair
Are There Any Limits to High Pressure Die Casting?
Of course, no process is perfect. We’re always honest with our customers when a part isn’t suitable for HPDC.
Typical limitations include:
- Wall thickness: Very thick sections (>5 mm) are not ideal due to internal porosity.
- Tooling cost: HPDC molds are expensive, especially for low-volume projects.
- Welding: Aluminum parts from HPDC may have trapped gases, making them difficult to weld without degassing treatments.
If your part has extreme thickness changes or only needs a few hundred units, we may recommend other casting methods.
What Kind of Buyers Choose HPDC — And Why?
Most of our HPDC customers are B2B clients who prioritize dimensional consistency, smooth finishes, and cost-effective mass production. Industries that rely on HPDC include:
- Automotive: EV controller boxes, gearbox covers
- Medical: Diagnostic equipment housings
- Energy: LED and solar lighting enclosures
- Industrial machinery: Precision brackets and frames
These buyers typically order in quantities of 5,000 pcs or more and require tolerances within ±0.10 mm. They often need painting or powder coating post-casting, which HPDC surfaces accept well.
When We Recommend Other Processes Instead of HPDC
We don’t push HPDC on every project. Sometimes, other casting methods make more sense. We guide buyers through this evaluation based on three main factors:
| Project Type | Better Process Alternative |
|---|---|
| Low-volume prototyping | Gravity casting or machining |
| Large, thick-walled structures | Sand casting or LPDC |
| Extreme ductility needed post-cast | Forging or billet machining |
When tooling budget is limited or surface finish isn’t critical, we help our customers balance cost and performance by choosing the right method from the start.
If you’re considering aluminum die casting for your parts, especially high volume or tight-tolerance products, high pressure die casting may be the answer. But if it’s not, we’ll tell you that too.
We’ve been manufacturing aluminum parts for over 20 years, and we’re here to share that experience with you—without the hard sell.
Searching for High-Quality for Aluminum Parts?
You’ve come to the right place! Yongzhu Casting is a certified die casting manufacturer with over 20 years of expertise in the industry.
We have successfully completed numerous die casting projects for Aluminum casting parts, particularly in your industry.
Zhejiang Yongzhu Casting Technology Co., Ltd.
Location: Zhejiang, China
Company type: Manufacturers, Producers, Wholesalers
Year Founded: 2004
Main Products: Aluminium die casting, Mold Making, Die Casting, Sand Casting, Gravity Casting
Leading Chinese producer Yongzhu Casting is formerly known as Hangzhou Higer Metal Products Co., Ltd., was established in 2004.
With 20 years of experience in the industry, we are a specialized manufacturer in Aluminum casting and Machining.
Our products are widely used in various applications such as Automotive, Energy, Lighting, Medical, Home Furnishings, Machinery & Equipment etc. Below are our advantages:
Design Review & DFM Support
Our professionals will evaluate your designs and provide suggestions for cost savings. Additionally, we offer Design for Manufacturing (DFM) assistance and conduct mold flow analyses to facilitate efficient production.
State-of-the-Art Manufacturing Equipment
Our facility is equipped with advanced hot-chamber and cold-chamber die casting machinery for aluminum and zinc production.
We also utilize high-precision CNC machines in a temperature-controlled workshop, featuring 3-Axis, 4-Axis and 5-Axis setups to manage any project you have.
Rigorous Quality Control Measures
Our dedicated quality control team ensures that all parts meet the highest standards of quality and consistency. We employ high-accuracy measurement instruments, including CMM, spectrometers, and X-ray detectors.
Comprehensive Surface Treatment Options
We provide a variety of surface finishing techniques for your precision die casting components. Our in-house services include cleaning, polishing, anodizing, shot blasting, and painting.
Flexible Project Acceptance
While larger manufacturers often shy away from low-volume projects, and smaller ones may struggle with quality, Yongzhu Casting stands apart. We prioritize customer satisfaction and willingly accept high-mix, low-volume projects like yours.
