Molten metal.
Absolute tolerance.
10,000 PSI. 200 milliseconds. ±0.002 inches. Six consecutive zero-finding audits. Aluminum die castings for automotive, electronics, and industrial OEMs who can't afford a miss.
Trusted by engineers at automotive tier-ones, consumer electronics OEMs, and industrial manufacturers
Every phase.
Every tolerance.
Scroll to advance through the casting lifecycle. Each card carries a downloadable engineering artifact.
Tooling Design & DFM Analysis
Design for Manufacturability
Before a single chip of steel is cut, our tooling engineers run your geometry through a 47-point DFM checklist. Draft angles, wall thickness uniformity, gate location, and parting line position are optimized in simulation before the die is cut.
Tool Steel Machining
H13 Hot-Work Tool Steel
Die halves machined from H13 hot-work tool steel on 5-axis CNC. Surface finish Ra 0.4 μm on cavity walls. Hardened to 44–48 HRC before EDM finishing of fine features.
First Article Inspection
PPAP Level 3 Documentation
First 30 shots are dimensionally characterized on our Zeiss CMM. Every critical-to-function dimension is reported against nominal. No production release without written FAI approval.
Production Ramp
Shot-to-Shot Process Control
Once FAI is approved, we ramp from 500-piece trial to full production. Every machine cycle is logged — shot weight, fill time, die temperature, intensification pressure. SPC charts run live on the floor.
Secondary Machining
Net-Shape to Final Dimension
Critical bores, threaded holes, and sealing surfaces are finish-machined in a single fixturing setup. Our cell links casting to machining with zero re-inspection between operations.
Surface Finishing
Shot Blast · Anodize · Powder Coat
In-house shot blast, chemical conversion coating (Alodine 1200), Type II anodize, and powder coat. EMI shielding gasket grooves finished to Rz ≤ 3.2 μm for electronics enclosures.
Final Inspection & Shipment
Zero-Defect Delivery Protocol
Every pallet ships with a Certificate of Conformance and dimensional data package. Outgoing AQL 0.65. Six consecutive external audits — IATF 16949 and ISO 9001 — with zero major findings.
Material science meets
process control.
Qualified Die Casting Alloys
| Alloy | Tensile | Density | Shrinkage | Best For |
|---|---|---|---|---|
| A380default | 47 ksi | 0.098 lb/in³ | 0.005 in/in | General purpose, housings, brackets |
| A383 | 45 ksi | 0.097 lb/in³ | 0.004 in/in | Complex thin-wall, electronics enclosures |
| A360 | 46 ksi | 0.095 lb/in³ | 0.004 in/in | Pressure tightness, corrosion resistance |
| ZA-8 | 54 ksi | 0.227 lb/in³ | 0.007 in/in | High strength, bearing surfaces |
| Zamak 3 | 41 ksi | 0.240 lb/in³ | 0.007 in/in | High-volume consumer hardware |
Six audits.
Zero findings.
"Six audits in, zero findings. Our supplier quality team uses Diecast as the benchmark when we're evaluating new casting sources."
"We replaced three machined aluminum parts with a single net-shape casting. Unit cost dropped 38% and lead time went from 6 weeks to 10 days."
"The DFM review caught a wall thickness issue that would have caused porosity in our EMI shielding groove. Saved us a tooling re-cut."
Your part,
our process.
Send us your STEP file and volume requirements. We'll return a DFM review, alloy recommendation, and budgetary quote within 2 business days.