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Lightweight aluminium components for efficient series production
Die casting
Die casting enables the automated mass production of complex aluminium components with high dimensional accuracy, thin-walled geometries and excellent surface quality. The process is particularly cost-effective for medium to high production volumes.
Customer benefits: Design engineers benefit from lightweight, thin-walled and functionally integrated components. Purchasing managers benefit from short cycle times, stable processes, high repeatability and cost-effective series production costs.
What is die casting?
Die casting is a highly efficient casting process in which molten aluminium is forced into a permanent steel mould under high pressure and at high speed. This produces precise, complex and thin-walled metal components with good dimensional accuracy.
The process is particularly well-suited to automated mass production. Low unit costs can be achieved thanks to short cycle times, high repeatability and reduced need for post-processing.
Die-casting is frequently used for aluminium components where lightweight construction, functional integration, dimensional accuracy and cost-effective mass production are key priorities.
Benefits of die casting
- High cost-effectiveness for medium and high production volumes
- Short cycle times
- High dimensional accuracy and repeatability
- Excellent surface quality
- Thin-walled and complex geometries possible
- Well-suited to lightweight construction
- Reduced post-processing thanks to manufacturing close to the final contour
Typical applications
Die cast components are frequently used in mechanical engineering, electrical engineering, building services engineering, vehicle manufacturing, the consumer goods industry, medical technology and in many technical mass-produced products.
What is die casting?
Die casting is a highly efficient casting process in which molten aluminium is forced into a permanent steel mould under high pressure and at high speed. This produces precise, complex and thin-walled metal components with good dimensional accuracy.
The process is particularly well-suited to automated mass production. Low unit costs can be achieved thanks to short cycle times, high repeatability and reduced need for post-processing.
Die-casting is frequently used for aluminium components where lightweight construction, functional integration, dimensional accuracy and cost-effective mass production are key priorities.
Benefits of die casting
- High cost-effectiveness for medium and high production volumes
- Short cycle times
- High dimensional accuracy and repeatability
- Excellent surface quality
- Thin-walled and complex geometries possible
- Well-suited to lightweight construction
- Reduced post-processing thanks to manufacturing close to the final contour
Typical applications
Die cast components are frequently used in mechanical engineering, electrical engineering, building services engineering, vehicle manufacturing, the consumer goods industry, medical technology and in many technical mass-produced products.
What is gravity die-casting?
Gravity die-casting is a casting process in which molten metal is poured into a reusable permanent metal mould, known as a die. Unlike sand casting, the mould is not destroyed after each casting but is reused multiple times.
The process is particularly suitable for aluminium and light metal alloys, as well as for components with stable geometries, good dimensional accuracy and consistent quality. The permanent metal mould ensures controlled solidification, which contributes to good mechanical properties and a high degree of reproducibility.
Benefits of gravity die-casting
- Reusable permanent moulds
- Good dimensional accuracy
- Good surface quality
- Stable and reproducible processes
- Good mechanical properties
- Cost-effective for medium production runs
- Suitable for aluminium and light-metal components
Typical applications
Die-cast components are used in mechanical engineering, vehicle manufacturing, plant engineering, electrical engineering, building services engineering, and in technical mass-produced components made from aluminium and light metal alloys.
Which method is suitable in which circumstances?
High-pressure die-casting is particularly suitable for large production runs, thin-walled components and short cycle times. Low-pressure die-casting is the ideal solution for robust and leak-proof aluminium components with higher requirements in terms of microstructure quality and strength. Gravity die-casting offers a cost-effective solution for dimensionally accurate castings with stable geometries and medium to high production volumes.
Facts & figures
Materials
Aluminium and zinc alloys in accordance with current norms and standards.
Weight per piece
From 10 g up to 10 kg.
Production volumes
Medium and large series.
Machining Capabilities
All standard machining methods, CNC and conventional machining.
Surface treatment
Pickling and passivation, burnishing, vapour and thin-film treatment, electropolishing, anodising, grinding, priming and lacquering, blasting, chrome plating, nickel plating, galvanising.
Production examples
