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Die Casting and High Pressure Die Casting (HPDC): A Complete Guide to Materials, Processes, and Precision Parts
Release time:
Sep 09,2025
Introduction: What Is Die Casting?
Die casting is a widely used process for manufacturing complex metal parts that have high accuracy and a smooth surface finish. The process involves injecting metal molten into a cavity of a mold under pressure. The component is strong and dimensionally stable, with minimal post-processing.
Die casting is a key component in the supply chain for CNC machining parts and precision components. Die casting is used in industries such as automotive and aerospace. Electronics and robotics also rely on parts because of their cost-efficiency and repeatability.
High Pressure Die Casting (HPDC) is one of the most popular casting methods due to its ability for producing intricate geometries in large scale. We will examine the differences between Die Casting, HPDC, Gravity Casting and the advantages Die cast Aluminum Materials.
What is high pressure die casting (HPDC)?
High Pressure Die Casting (abbreviated HPDC) is a special method of die-casting in which molten steel is forced into a mold with very high pressure. This pressure is typically between 10-175MPa.
HPDC Features:
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High dimensional accuracy (tight tolerances up to +-0.1 mm).
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Smooth surface finishes (reducing secondary machining).
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Thin Wall Sections (as small as 1-2mm).
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High Production Rates
HPDC is especially suitable for aluminum die-cast material as well as metal die-cast components. It offers a balance of weight reduction and mechanical performance.
Die Casting vs. Gravity Casting
Die Casting is a general term that refers to the process of forcing molten metal through a mold. However, this method can be used in many different ways:
1. Gravity Casting
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Fill the mold using gravity.
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A slower process than HPDC
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Produce components with lower porousness, and improved mechanical properties.
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More suitable for thicker walls.
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Commonly used in engine components, pump housings and heavy-duty component.
2. High Pressure Die Casting (HPDC)
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Filling molds quickly with pressure injection is possible.
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Provides superior accuracy and surface finish .
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Suitable for production of lightweight, complex parts in high volume.
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Widely used in automobile housings, electronic enclosures and aerospace brackets.
The choice between the two methods depends on factors like material type, complexity of parts, mechanical requirements and production volume.
Common Die Cast Metals and Materials
The performance requirements of different industries are unique, and so selecting the best die-cast metal for your industry is crucial. Here are some of the most popular materials:
| Material | Key Features | Examples of Applications |
|---|---|---|
| Die Cast Aluminum | Excellent thermal conductivity, lightweight, corrosion resistant, and lightweight | Electronics, automotive housings and aerospace parts |
| Die Cast Zinc | Easy to cast and cost-effective | Consumer goods, connectors, handles |
| Die Cast Magnesium | Strong, lightest structural metal, good EMI shielding | Aerospace, robotics, electronics enclosures |
| Die Cast Copper/Brass | Outstanding electrical conductivity with wear resistance | Electrical parts, plumbing and industrial valves |
Die Cast Aluminum Material is the most popular among them due to its combination of light weight, strength and affordability.
Why Choose Die Casting for Industrial Applications?
Die casting is a growing industry. This is not a coincidence. Die casting has several advantages:
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High efficiency: HPDC allows rapid production of thousands identical parts with minimal variations.
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Cost savings: Tooling cost is high, but part costs fall significantly when scaled up.
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Flexibility in design: Able to produce intricate shapes that are difficult or expensive with traditional machining.
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Material properties: Lightweight metals such as aluminum and magnesium reduce product weight without compromising its strength.
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Post Machining Compatibility Die-cast parts can be CNC machined for surfaces, threads or assembly features.
Die Casting: The Role of CNC Machining
Although die castings are produced with tight tolerances, certain applications may require secondary CNC machining on critical surfaces. CNC Machining is the answer.
Die cast parts are typically subjected to typical CNC operations.
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Milling (flatness, slots, contours)
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Turning (shafts, circular features)
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Drilling & Tapping
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Surface Treatment Preparation
Combining die casting and CNC machining allows manufacturers to produce high-performance, cost-effective parts.
Shenzhen Yixin Precision: Your Partner in Die Casting & CNC Machining
Shenzhen Yixin Precision specializes in custom parts manufacturing. We also offer CNC machining and die casting services . We have over 20 years experience and provide a One-Stop Solution.
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Advanced Die Casting for Aluminum, Zinc, and Magnesium.
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CNC Machining Expertise 3-axis, 5-axis and 4-axis equipment is available for complex geometries.
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ISO-Certified Quality Control
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Flexible production is applicable to small batch prototypes as well as large-scale production runs.
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Surface treatment options include anodizing and powder coating.
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Fast global delivery for clients in the robotics, aerospace and automotive industries.
Yixin Precision can provide you with cost efficiency, accuracy and reliable performance.
The conclusion of the article is:
Die casting is still a key component of modern manufacturing, and HPDC in particular, remains a staple. It is ideal for die casting aluminum, zinc and magnesium.
Die casting is a cost-effective way to produce large quantities of parts and can be finished precisely for critical applications.
If you are looking for a reliable supplier of Die Casting Parts that can provide CNC machining assistance, Shenzhen Yixin Precision will be your partner.
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