Expert Aluminum Die Casting Manufacturer

Quality Aluminum Die Casting Manufacturer

The die casting process forms precision metal parts using high pressure to completely fill all cavities within a mold. High pressure die casting works with numerous non-ferrous metals, such as aluminum, and magnesium, among others. The die itself is made from tool steel, to ensure long-term functionality with minimal production wear. This fabrication method provides an ideal solution for producing complex designs in high volumes.

At DyCast Specialties Corporation, we specialize in providing high–quality aluminum die casting services for a wide variety of industries and applications. As an aluminum die casting manufacturer, we are committed to delivering precision and durability.

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Why Aluminum?

Aluminum sees frequent use in die castings for producing lightweight, intricate designs. At DyCast Specialties, we work with the following aluminum alloys:

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Regardless of the specific type of aluminum selected for individual projects, aluminum in general offers various beneficial characteristics:

Conductivity. Aluminum conducts electricity and thermal energy well.
Dimensional stability. This metal maintains good dimensional stability, even in parts with very thin walls. Aluminum’s stability also makes it an excellent choice for complex parts.
Mechanical properties. Aluminum offers a good degree of hardness, shear strength, and tensile strength. These and other mechanical properties make aluminum a good choice for commercial and industrial parts that require reliable long-term performance.
Resistance to corrosion. Aluminum resists corrosion and oxidation, making it useful for mitigating the risk of rust in indoor or outdoor applications.
Strength. Aluminum is a strong metal with an excellent strength-to-weight ratio, even maintaining its strength at high temperatures.
Weight. Aluminum is a lightweight metal, especially compared to steel and other popular manufacturing materials. This is important for designing fuel-efficient vehicles, aerospace parts, handheld consumer goods, construction elements, and other products where lower component weight may improve performance.

Common Applications

A wide variety of industries rely on aluminum for its versatility and compatibility with the die casting process. Some of the most popular applications of aluminum die casting parts include:

Appliances. Die casting produces identical and interchangeable parts, which is crucial for mass-manufactured consumer appliances.
Automotive. Aluminum alloy die casting produces strong and lightweight automotive parts, which enhances fuel efficiency for automobiles and heavy trucks.
Electric motors and fluid pump motors. Aluminum has excellent dimensional stability, even at the high temperatures found in motor and pump operation.
Hand tools. Aluminum tools are lightweight, strong, and easy to handle.
Hardware (fasteners). Aluminum fasteners withstand corrosion and environmental wear for a long-lasting hold.
LED lighting. Aluminum components conduct electricity well, contributing to the efficiency of LED lighting.
Medical/healthcare. Medical devices need to be strong, lightweight, and rigid for easy use by medical professionals.
Military. Aluminum is a strong, cost-effective material choice for vehicle components, electronics, and structural components.
Recreational (interior/exterior parts). Aluminum fasteners, grommets, and other hardware are strong, rigid, and resistant to environmental damage.
Retail scanning. Die casting produces housings and hardware components used in retail scanning equipment.
Robotic automation. Industrial systems require strong, high-quality aluminum components that can integrate with other hardware.
Security. Die casting aluminum produces high-precision components for smart locks, security cameras, and other security devices.
Video conferencing. Precision video conferencing system parts and housings are often produced using die casting.

Quality Aluminum Die Casts from DyCast Specialties

At DyCast Specialties Corporation, we provide complete high-pressure aluminum die casting services. We manage the entire process, from the initial design through machining, finishing, and shipping. Our facility includes an in-house machining center with tolerance capabilities within +/- 0.00025 of an inch. Our additional processes include coatings, annealing, testing, inspecting, and assembly.

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Specifications

Die Cast Alloys

Aluminum Alloys: 380, 383, 413

Die Cast Cells

Aluminum – Hiqh Pressure:

(1) – 725 ton Die Casting Machine
(2) – 600 ton Die Casting Machine
(3) – 600LB/Hour – 4800LB Capacity Furnace

Tolerance

+/- 0.0025

Maximum Weight

10 Pound

Tooling Construction

All molds are constructed from Premium H-13 tool steel and are heat treated to 46-48 R/C.
Tooling, molds & dies are produced through Dycast Specialties’ in-house tooling department, out-sourced tooling vendors, and overseas vendors.

Mold Longevity

Up to 100,000 shots

Tooling concept

10″ x 12″ Standard DME Unit Dies
12″ x 15″ HD DME Unit Dies
12″ x 15″ Standard DME Unit Dies

15″ x 18″ HD DME Unit Dies
8″ x 8″ House Inserts
Standard Cavity Retainer Sets

Equipment List

Trim Press Cells :

3-6 ton Trim Press
1-20 ton Trim Press
1-35 ton Trim Press

10 – 8 ton Trim Press
2-10 ton Trim Press

CNC Machining

Machining Centers :

3 – CNC Vertical milling center with pallet changer
3 – CNC Vertical milling machine

Machine fixtures and CNC centers capable of producing tolerances of +/- . 00025

Deburring

Tumble Deburring:

Commercial type hardware finish.
Utilizes a part on part barrel action to polish the casting surface, remove flash, and reduce sharp edges.

Finishing

Vibratory Finishing:

Premium visual cosmetics
Utilizes plastic and ceramic medias to polish the casting surface and reduce sharp edges.

Additional Process

Annealing
Assembly
Black Zinc Chromate
Bright Zinc Chromate
Chromate Conversion
Clear Anodizing
E-Coating

Liquid Paint
Pad Printing
Powder Coat Paint
Shot Bead Blasting
X-Ray
Yellow Zinc Chromate