Comprehensive Mold Solutions
Aluminium Die Casting & Tooling
Die design, casting, trimming and machining for aluminium and zinc components, from prototype quantities to production.
Cast shapes, machined tolerances
Die casting gives you complex aluminium or zinc geometry in one shot, at a cost per part that machining cannot match in volume. The engineering effort goes into the die design: gate position, runner layout, cooling and ejection decide whether the casting is sound and whether the cycle is short.
We design and build the die, run the trials and can machine the casting to final tolerances if you need finished components rather than raw castings.
- Aluminium and zinc die casting, hot and cold chamber
- Die design and thermal layout in-house
- X-ray and pressure testing for structural parts
- CNC finishing, drilling, tapping and surface treatment
Casting capabilities
Aluminium castings
Structural and cosmetic castings for automotive, power tool and industrial housings.
Zinc castings
Small, thin-walled, high-accuracy parts where surface finish and detail matter.
Machining after casting
Facing, boring, drilling, tapping and thread milling to bring castings to final tolerance.
Dies and tooling
Single and multi-cavity dies, with spare cores and inserts so maintenance does not stop production.
Typical process window
| Parameter | Range |
|---|---|
| Materials | ADC12, A380, A360, ZAMAK 3 and 5 |
| Part weight | 50 g to 8 kg (aluminium) |
| Wall thickness | Typically 1.5-4 mm, subject to flow analysis |
| Die lead time | 35-60 days depending on complexity |
| As-cast tolerance | Per GB/T 6414 or your drawing standard |
| Finishing | Sand blasting, shot blasting, powder coating, anodising, machining |
How a casting project runs
01
Feasibility and quoting
We review wall thickness, draft, radii and machining allowance and confirm the die concept.
02
Die design
Runner, gate, overflow, cooling and ejection layout, plus thermal balance analysis.
03
Die manufacture and trial
Tool build, first castings, X-ray or sectioning where the part is structural.
04
Validation
Dimensional and visual approval, then process parameters frozen for production.
05
Production and finishing
Casting with in-process checks, followed by trimming, machining and surface treatment.
Frequently asked questions
How many parts do I need before die casting makes sense?
It depends on part size, but die casting normally beats machining from solid once annual volume reaches the low thousands. Send the drawing and the volume and we will compare both routes.
Can you supply machined, finished castings?
Yes — casting, trimming, machining, surface treatment and inspection can all be delivered as a finished part, which removes the logistics of moving castings between suppliers.
How do you control porosity?
Through die design first: gate position, runner and overflow layout, thermal balance and venting. X-ray or leak testing can be added where the part is safety-related.
What tooling is needed besides the die?
Usually trimming fixtures, machining fixtures and gauges. They are quoted with the die so the full programme cost is visible up front.
Related services
Plastic Injection Molding · CNC Machining & Prototyping · Secondary Operations · Mold Design & Engineering · Final Assembly & Packaging
Learn more about YOYO Mould, or send us your drawings for a quotation.
Send your casting and we will quote the die and the part
Include the annual volume, the alloy and any machining requirements — we will come back with both the tooling and the piece price.