What products are made by die casting?
In simple terms, a product of die casting is any metal part whose final shape is formed mainly inside a hardened steel die by injecting molten metal at high pressure. Instead of machining everything from solid or using sand molds for each part, the die cavity defines most of the geometry.
Typical die cast parts include:
- Thin-wall housings and covers
- Structural brackets and frames
- Heat sinks and cooling components
- Pump and valve bodies
- Motor, gearbox and compressor components
- Enclosures for electronics, lighting and telecom equipment
Most industrial die castings today are made from aluminum, zinc or magnesium alloys, chosen for their balance of weight, strength, cost and corrosion resistance. This article focuses on real examples so you can see where die casting is used in practice.
If you need a more detailed, engineering-focused discussion of aluminum die cast product types and design tips, you can also read our separate guide “Aluminum Die Casting Products: Types, Applications & Design Tips.”
Automotive transmission housings and clutch covers
One of the most familiar examples of die cast parts is the transmission housing in cars and light commercial vehicles.
These components must:
- Enclose gears, shafts and oil passages
- Provide accurate locations for bearings and seals
- Integrate mounting bosses, ribs and flanges
High-pressure die casting is well suited because it can:
- Form complex internal and external geometry in one shot
- Achieve thin walls and integrated ribs for stiffness
- Deliver consistent dimensions across large production volumes
Critical surfaces such as bearing seats, sealing faces and threaded holes are machined after casting, but most of the shape comes from the die.
Electric vehicle motor housings and inverter casings
Electrification has created a new family of die cast components in EVs and hybrid vehicles:
- Traction motor housings and stator carriers
- End bells and rotor supports
- Inverter and power electronics casings
These parts combine structural, thermal and electrical functions:
- They hold the motor or electronics securely in place
- They remove heat from windings and power devices
- They protect sensitive components from dust, water and vibration
Die casting allows designers to integrate cooling fins, cable routing, mounting lugs and connector interfaces into a single compact part, instead of welding or bolting multiple pieces together.
Industrial pump bodies and compressor parts
In industrial machinery, many pump bodies and compressor housings are manufactured as die castings, especially where weight and shape complexity matter:
- Pump volutes and casings
- Compressor crankcases and cylinder heads
- End covers with integrated mounting features
Reasons this process works well:
- Flow passages and internal shapes can be formed directly in the die
- Mounting feet, supports and bosses can be cast into the outer geometry
- Aluminum or other light alloys reduce weight compared with cast iron, making installation and maintenance easier
When fluids or environments are aggressive, appropriate coatings, inserts or liners are used to ensure long-term performance.
Gearbox housings and motor frames
Another common group of die cast parts is gearbox and motor components:
- Gearbox housings and inspection covers
- Electric motor frames and end shields
- Housings for mechanical drives and actuators
Die casting offers several advantages here:
- Thin walls and ribs provide stiffness without heavy sections
- Cooling fins can be cast onto the outer surfaces
- Complex shapes for cable entries, mounting feet and flanges can be formed in the die
Again, critical aligning features are machined, but the majority of the housing is defined by the casting process.
LED street light housings and heat sinks
Modern LED lighting is a very visible example of die casting in everyday life.
Typical die cast parts in lighting include:
- Street light bodies with integrated heat sinks
- Floodlight housings with fins and mounting brackets
- High-bay and tunnel light enclosures
These parts must:
- Conduct heat away from LEDs and drivers
- Survive outdoor weather, vibration and impact
- Offer a pleasing appearance that can be painted or powder-coated
Die casting enables complex fin geometry and smooth surfaces, while keeping weight under control and allowing easy mounting on poles or structures.
Enclosures for electronics and telecom equipment
Many robust electronics and telecom enclosures are made as die cast parts:
- Outdoor radio and base station housings
- Power supply and drive enclosures
- Junction boxes and distribution boxes
These components provide:
- Mechanical protection for printed circuit boards and modules
- Environmental sealing against moisture, dust and pollutants
- A degree of electromagnetic shielding, especially when combined with suitable gaskets and coatings
Die casting allows designers to incorporate bosses, connector cut-outs, cable glands and cooling features directly into the casting, reducing secondary operations.
Power tool gear housings and industrial hand tool bodies
If you open many professional power tools, you’ll find die cast components inside:
- Gear housings for grinders, saws and drills
- Motor housings and fan covers
- Structural halves of heavy-duty tools and industrial hand machines
These parts need to be:
- Compact and light enough to handle comfortably
- Strong enough to support gears, bearings and loads
- Resistant to vibration and occasional impact
Die cast designs can combine ergonomic outer shapes with internal ribs, bosses and cavities optimized for strength and space.
Valve bodies, manifolds and fluid control blocks
In pneumatic and hydraulic systems, many valve bodies, manifolds and control blocks are made using die casting:
- Multi-port manifolds with intersecting internal channels
- Valve housings with integrated brackets and ports
- Compact bodies for measuring and metering devices
Benefits of die casting in fluid control:
- Complex internal passages can be cast rather than drilled from solid
- Weight is lower than traditional steel or brass designs
- External geometry (mounting flanges, bolt patterns, sensor ports) can be tailored to the application
For higher pressures or corrosive media, die castings may be combined with surface treatments or internal components to achieve the required performance.
Building hardware and architectural fittings
In the building and architectural sector, die cast parts appear in many types of hardware and fittings:
- Bodies and arms for window and door hardware
- Brackets and joints in façade and curtain wall systems
- Components in balustrades, railings and shading systems
Here the priorities combine appearance and function:
- Clean, repeatable shape and surface quality
- Adequate strength and stiffness for loads
- Finishing by painting, powder coating or other treatments
The die casting process allows designers to create sharp lines, curved forms, logos and textured surfaces directly in the mold.
Sports, leisure and other niche die cast parts
Beyond heavy industry, die cast components appear in various sports and leisure products, as well as other specialized equipment:
- Structural parts in fitness and gym equipment
- Brackets, hubs and joints in bikes and scooters
- Components in camera rigs, stage lighting and musical equipment
In these products, die cast parts help:
- Reduce weight while maintaining stiffness
- Enable ergonomic and visually distinctive shapes
- Integrate mounting points and adjustment features into one piece
Often, die casting competes with machining, forging or welding; the final decision depends on annual volume, functional requirements and styling freedom.
How can you tell if a part is a good candidate for die casting?
Looking across these examples, most successful die cast parts share common characteristics. A design is usually a good candidate for die casting if:
- Annual or lifetime volume is high enough to justify tooling
- Geometry is three-dimensional and reasonably complex, with ribs, bosses, cavities or details that are costly to machine or weld
- Target wall thickness is in a realistic range for the chosen alloy and process
- Only some areas need very tight tolerances; you are prepared to machine critical features and leave non-critical surfaces as-cast
- Loads, environment and operating temperatures are compatible with typical die casting alloys and process capability
If these conditions are met, it makes sense to discuss the part with a die casting supplier and request a feasibility review.
When is die casting not the right manufacturing route?
There are also cases where die casting is not the best option. Alternative processes may be more appropriate when:
- Annual quantity is very low and will never recover the tooling investment
- The part is very large or extremely heavy, beyond practical die casting machine capacity
- Very high strength, ductility or impact toughness is required – for example, heavily loaded safety-critical structures
- The design requires substantial welding, bending or forming after shaping
- The component must operate at temperatures beyond the limits of common die casting alloys, where strength and dimensional stability degrade
In those situations, engineers often choose sand casting, gravity casting, forging, fabrication or full machining from plate or bar.
Working with Yongzhu Casting on new die cast components
If you are looking at a drawing or 3D model and wondering, “Could this be a product of die casting?”, it usually helps to involve a foundry early.
At Yongzhu Casting, we focus on aluminum die cast parts for automotive, industrial, lighting and other applications. We support customers by:
- Reviewing your design to evaluate suitability for die casting
- Suggesting design adjustments that improve filling, reduce porosity and stabilize tolerances
- Recommending alloy families and finishing options based on your environment and appearance requirements
- Designing and building tooling, then providing samples and dimensional reports for validation
If one of your parts looks similar to the examples in this article, or you suspect die casting could reduce cost and weight, you are welcome to send us your drawings and basic requirements. We can help you decide whether die casting is the right manufacturing route and outline a practical path from concept to stable mass production.
FAQ
FAQ 1: What metals are most commonly used for die casting products and how do they differ?
The three most common die casting metals are aluminum, zinc and magnesium. Aluminum alloys are popular for housings, brackets and structural parts because they combine low weight, good strength and reasonable corrosion resistance. Zinc die castings are usually chosen for smaller, highly detailed parts such as precision hardware or consumer components, where excellent fluidity and fine feature reproduction are important. Magnesium offers the lowest density of the three and is used where weight reduction is critical, for example in some electronics or automotive interior structures, but tooling and alloy costs are higher and process control is more demanding.
FAQ 2: How thin can walls be on a die cast part, and what limits the minimum wall thickness?
For many aluminum die castings, practical wall thicknesses are in the range of about 2–4 mm on medium-size parts. Very small parts or special alloys and processes can sometimes go below 2 mm, but this requires very careful gating, venting and die temperature control. The minimum wall thickness is limited by the ability to fill the cavity before the metal solidifies, the risk of misruns and cold shuts, and the need for sufficient strength in the wall after machining and finishing. In early design, it is usually better to aim for a robust, realistic thickness rather than chasing the absolute minimum.
FAQ 3: How does die casting compare with machining from solid in terms of cost and performance?
Machining from solid is flexible and has almost no tooling cost, but material waste and cycle time per part are high. Die casting needs significant upfront investment in tooling, but once the die is built, the cost per piece is much lower at medium and high volumes. In terms of performance, machined parts can achieve very tight tolerances and excellent fatigue strength if they are made from wrought alloys. Die cast parts generally have a lower fatigue limit and more internal porosity, but are perfectly adequate for many housings, covers and brackets. The usual rule of thumb is to machine prototypes and very low-volume parts, and to switch to die casting when geometry and demand justify a dedicated die.
FAQ 4: What information should I prepare before asking for a quote on die cast components?
To receive realistic quotations and technical feedback, it is helpful to prepare 3D models and drawings with clearly marked critical features and tolerances. You should also describe the expected annual volume and total program life, the operating environment (temperature, fluids, outdoor or indoor use), and any special requirements such as leak tests, pressure tests, X-ray or CT inspection, and surface finishes. If you already use a machined or fabricated part and want to convert it to a die casting, sharing the current cost structure and pain points also helps suppliers propose a sensible solution.
FAQ 5: Can an existing welded or fabricated assembly be converted into a single die cast part?
In many cases, yes. One of the strengths of die casting is the possibility to integrate several welded or bolted components into a single, more complex casting. However, this is not automatic. The combined part must still meet realistic wall thickness, draft and process constraints, and you may need to redesign some features so that they can be formed in a die and machined efficiently. A typical approach is to let a die casting supplier review the current assembly, identify which parts can be merged, and propose a new casting concept with a clear plan for machining and inspection.
FAQ 6: How are quality and defects controlled in die cast products for demanding applications?
For demanding applications such as automotive, fluid power or safety-related equipment, quality control goes beyond simple visual checks. Suppliers define a process window for metal temperature, shot speed, die temperature and lubrication, and then monitor key parameters during production. They may use X-ray or CT inspection on initial samples and periodically in series production to keep porosity, inclusions and other internal defects within agreed limits. Dimensional checks and functional tests such as leak tests, pressure tests and proof-load tests are also defined in the control plan so that the die cast components consistently meet customer requirements.
