Process Overview
High-pressure die casting (HPDC) is the engine of modern mass manufacturing. Molten aluminum or zinc is injected into a hardened steel die at 10–175 MPa and plunger speeds of 30–120 m/s, filling the cavity in milliseconds. Cycle times of 30–90 seconds per shot mean a single HPDC machine can produce 500–1,200 parts per shift. The dimensional consistency is remarkable: part-to-part variation of ±0.05mm is routine on well-maintained tooling, and surface finishes of Ra 0.8–3.2μm eliminate painting prep for most applications. HPDC is the dominant process for automotive structural components, telecom base station housings, and consumer electronics enclosures — any application where volume is high and per-part cost must be minimized. Our engineering team reviews HPDC drawings for draft angles, wall thickness uniformity, and gate location to maximize die life and minimize porosity.
Key Advantages
- Cycle time 30–90 seconds — 500 to 1,200+ parts per shift on a single machine
- Part-to-part dimensional consistency ±0.05mm — CT5 to CT7 tolerance grade
- Surface finish Ra 0.8–3.2μm directly from die — minimal secondary finishing required
- Thin wall capability: aluminum down to 0.8mm, zinc down to 0.5mm
- Complex shapes with integrated inserts, threads, and bosses in one shot
- Lowest per-part cost at volumes above 5,000 pieces — die amortized over 100,000+ shots
Technical Specifications
Process Flow
Step-by-step overview of our High-Pressure Die Casting workflow — from raw material to finished casting.
Typical Applications
Compatible Materials
Full Technical Specifications
Comprehensive process parameters for High-Pressure Die Casting — based on ISO 8062 / GB/T 6414 standards.
| Parameter | Value / Range | Notes |
|---|---|---|
| Tolerance Grade (ISO 8062) | CT5 – CT7 | Part-to-part consistency ±0.05 mm on good tooling |
| Dimensional Tolerance | ±0.1 mm – ±0.3 mm | Depends on part size and die condition |
| Surface Roughness (Ra) | 0.8 – 3.2 μm | Directly from die; minimal finishing required |
| Minimum Wall Thickness | Al: 0.8 mm; Zn: 0.5 mm | Thin-wall capability for lightweight design |
| Typical Weight Range | 0.05 kg – 25 kg | Larger parts up to 50 kg on request |
| Injection Pressure | 10 – 175 MPa | Plunger speed 30–120 m/s |
| Cycle Time | 30 – 90 seconds/shot | 500–1,200+ parts per shift |
| Typical Materials | ADC12, A380 Al, AlSi9Cu3, Zamak zinc, Mg alloys | Aluminum and zinc most common |
| Typical Applications | Automotive components, telecom housings, electronics enclosures, heat sinks | High-volume mass production |
| Die Life | 100,000 – 500,000+ shots | H13 tool steel dies; depends on alloy |
| Minimum Order Quantity | 5,000 pieces (economical) | Tooling cost amortized over volume |
| Lead Time (tooling) | 25 – 40 working days | Hardened steel die fabrication |
| Lead Time (production) | 15 – 25 working days | After tooling approval |
* All values are indicative. Actual achievable parameters depend on part geometry, alloy, and tooling design. Contact our engineers for drawing-specific assessment.