Die Casting Foundries – Types and Ordering Castings
Die casting foundries produce castings by injecting molten metal under high pressure into steel molds. They differ above all in the alloy cast and the type of machines, as well as in whether they design and build the molds themselves and whether they machine and finish the castings. These differences determine mold cost, lead time to production and the scope handled by a single supplier.
Types of Die Casting Foundries
| Type | Machines and Process | Typical Products |
|---|---|---|
| aluminum foundries | cold-chamber machines – the shot chamber is outside the molten metal, and metal is ladled into it in portions | housings, bodies, brackets, heat sinks |
| zinc alloy foundries | hot-chamber machines – the injection unit is submerged in the molten metal, which shortens the cycle | small, precise parts, hardware, decorative components |
| magnesium alloy foundries | hot- or cold-chamber machines, depending on casting size | lightweight housings, e.g. for electronics and power tools |
| low-pressure die casting foundries | metal rises from a sealed furnace into a metal mold under low gas pressure | automotive wheels, cylinder heads |
Aluminum is not cast on hot-chamber machines – molten aluminum would destroy the injection components submerged in it. That is why aluminum foundries use cold-chamber machines.
What to agree with a die casting foundry before placing an order
- Annual quantity and batch size – they determine the number of cavities in the die and the cost-effectiveness of the process.
- Die ownership – who owns the die, where it is stored and who covers the cost of refurbishing it.
- Die life – an aluminum die typically lasts tens or hundreds of thousands of cycles, depending on part geometry, steel grade and maintenance.
- Trial castings – how many pieces, which measurements and tests, the approval deadline and the scope of die corrections included in the price.
- Tolerances and machining allowances – the tolerance class, e.g. per PN-EN ISO 8062-3, and the surfaces intended for machining.
- Leak tightness – if the casting operates under pressure, the test method and the permissible leakage.
- Machining and finishing – whether the foundry supplies the casting as-cast, or machined and painted.
For a general approach to evaluating a supplier, see our guide: how to choose a die casting foundry.
Die Castings at Poznań Foundry
We die cast aluminum alloys – including EN AC-46200, 46500 and 47100 – in runs of up to 100,000 pieces per year, as well as in short runs and prototypes. We design dies in CAD/CAM with melt flow simulation, make them from tool steel on our own CNC machines, and cool and refurbish them. Castings are machined and painted in the same plant.
In short: die casting foundries differ by alloy (aluminum, zinc, magnesium) and machine type – aluminum is cast on cold-chamber machines. Before ordering, it is worth agreeing on annual volume, die ownership and life, trial casting rules, tolerances, leak tightness requirements and the scope of machining.
See also: die casting foundry equipment, how high-pressure die casting of aluminum works, when high-pressure die casting pays off i high-pressure die casting – our offer.
Looking for an aluminum die casting foundry? Send a drawing or 3D model to odlewnia@adjatech.pl or call: +48 61 662 43 37 (Mon–Fri 8:30 a.m.–4:30 p.m.).
Scope of services: foundry production capabilities.