High Pressure die casting

High Pressure Die Casting

What is High Pressure Die Casting

High-pressure die casting (HPDC) is a manufacturing process used to produce metal parts with high precision and efficiency. In HPDC, molten metal, typically aluminum or zinc alloys, is injected into a metal mold cavity at extremely high pressures, ranging from 1500 to 25,000 psi. This pressure ensures the metal fills the mold completely, creating intricate and detailed parts with excellent surface finish and dimensional accuracy. HPDC is widely utilized in various industries, including automotive, aerospace, and electronics, for the production of complex components in large quantities.

How High Pressure Die Casting Work?

High-pressure die casting commonly involves the sequential processes of mold preparation, injection, ejection, and post-casting treatment. While variations exist to meet specific product requirements, including vacuum die casting, slow-fill die casting, and semisolid metal processing (SSM), the general procedural steps are as follows:

  • Mold Preparation: The die cast mold is cleaned of impurities and lubricated with a release agent to prevent contamination and aid in part removal after injection.
  • Inject the Material: The two-part mold is sealed and injected with molten metal, using either the hot chamber or cold chamber method depending on the metal type. Hot chamber is used for metals like zinc, magnesium, and lead, while cold chamber is suited for aluminum, brass, and magnesium. Additionally, the cold chamber process offers flexibility with either horizontal or vertical injection.
  • Part Removal: After the part solidifies, the two-part cast can be opened and the part removed. the operator uses the ejector pin to release the mold’s cavity and push out the solidified casts.
  • Trimming: The final step of high-pressure die casting involves trimming the part using post-processing techniques, such as sawing and grinding, to remove excess material at the mold junction and injection point (sprue). The sprue can be recycled for future castings.

Advantages of High Pressure Die Casting


Fast production rates

High pressure casting process allows for the rapid injection of molten metal at high speeds, leading to significantly higher production rates compared to low-pressure or gravity casting methods.


Ability to create thin walls

High pressure die casting can obtain a thin wall thickness of under 0.40mm. The ability to produce thin walls not only contributes to weight reduction in the final products but also allows for the incorporation of inserts, commonly known as "co-cast" parts, such as screws and liners, during the casting process. This feature helps streamline assembly processes by reducing the overall number of components.


Ability to create complex geometry

High pressure die casting (HPDC) offers the ability to create complex geometries in metal components. This capability makes HPDC well-suited for applications where complex designs and precise shapes are essential, such as in automotive, aerospace, and electronics industries.


Good Quality Parts Manufactured

HPDC ensures top-notch quality with precise dimensional accuracy, superior surface finish, and minimal trimming requirements. This process delivers uniformity, easing plating, and offers optimum mechanical properties, making it ideal for high-quality components.


Long-lasting tools

High pressure die casting employs durable tools, known as dies, that withstand repeated use. This longevity reduces per-unit costs and makes HPDC economically efficient for large-scale production cycles.


Low cost for large-scale production

HPDC is cost-effective for large-scale production due to its fast cycle times, high production rates, and reusable dies. These factors contribute to lower per-unit costs, making it an economical choice for mass manufacturing.

High pressure die casting at Huayin

Choosing the right manufacturing process is crucial. At HuaYin, our team of experienced engineers offers expert advice and addresses queries in die casting services. With state-of-the-art facilities and efficient manufacturing plants, we ensure high-quality products. Benefit from fast lead times, quick online quotations, and free Design for Manufacturability (DFM) analysis upon uploading your design file. Rest assured, we deliver excellence at competitive market prices.


  • 01 Which Materials are Suitable for HPDC?

    Materials suitable for High-Pressure Die Casting (HPDC) include aluminum alloys, known for their lightweight strength, zinc alloys for intricate designs and magnesium alloys for weight reduction.

  • 02 What Industries Commonly Use HPDC?

    HPDC is commonly employed in industries such as automotive for manufacturing engine components and structural parts, aerospace for lightweight components, electronics for casings and connectors, and telecommunications for high-precision components.

  • 03 What Factors Affect the Cost of HPDC?

    The cost of High-Pressure Die Casting is influenced by factors such as design complexity, material choice, production volume, tooling and die costs, surface finish requirements, tolerances, post-casting processes, and material waste minimization. Balancing these factors is essential for cost-effectiveness in HPDC projects.

  • 04 How Does HPDC Compare to Other Casting Methods?

    High-Pressure Die Casting surpasses other casting methods in terms of speed, efficiency, the ability to produce complex shapes, and superior surface finishes. It is particularly advantageous for high-volume production due to its speed and cost-effectiveness.


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