Permanent Mold (Gravity Die) Casting – Production of Non‑Ferrous Metal Castings
Permanent Mold Casting — Technology for Modern Industry
Permanent mold (gravity die) casting is a modern process used to produce non‑ferrous castings such as aluminium (aluminum), brass, bronze and zinc. Using metal moulds/molds delivers high quality, crisp detail and outstanding dimensional repeatability. The method excels in serial production, combining durability and mechanical strength with reduced post‑processing. It’s ideal for automotive, aerospace, electronics, hardware and decorative components.
Aluminium (Aluminum) Permanent Mold Casting — Advanced Technology in Our Foundry
Precise and efficient aluminium (aluminum) castings tailored to your needs
Our aluminium foundry specialises in permanent mold (gravity die) casting, offering both standard and custom components in non‑ferrous alloys. We run the process on an advanced machine park that enables high‑quality aluminium/aluminum castings with tight tolerances, excellent surface finish and repeatable dimensions.
We operate modern equipment that ensures precise detail reproduction and optimal casting parameters:
Electric melting furnaces with 250–600 kg charge capacity, providing uniform melting of aluminium (aluminum) alloys and tight process temperature control.
Refining and modification units for aluminium/aluminum melts, eliminating impurities and tuning the mechanical properties of castings to individual specifications.
Casting stations for moulds/molds up to 300 × 300 × 300 mm, enabling production of smaller, high-precision aluminium/aluminum castings.
Permanent-mold (gravity-die) machines for forms up to 1400 × 1200 × 750 mm, allowing larger and more complex aluminium/aluminum castings with superior surface finish.
Thanks to modern technologies we deliver both serial aluminium castings and single‑piece runs for diverse industries, including automotive, aerospace and structural components. Where required, we provide post‑casting CNC finish machining to meet final tolerance and assembly needs.
For orders requiring greater flexibility, we can produce permanent molds beyond standard machine envelopes using a screw‑mechanism device, enabling aluminium/aluminum castings with atypical dimensions.
For serial production our molds are poured in an automatic cycle to ensure consistency and throughput. For short runs we use manual pouring, which relies on long‑standing expertise and precise control of metal and mold temperatures. This approach guarantees top quality and compliance with demanding standards.
By combining experience, modern technology and a flexible production approach, we offer aluminium/aluminum castings of the highest quality that meet the expectations of the most demanding clients.
We design and manufacture durable moulds/molds and cores for permanent mold casting
End‑to‑end support — from design to finished casting
Permanent‑mold tooling is created entirely in‑house, from concept to manufacture. Our design office uses advanced software for 3D modelling and analysis to develop cavity and gating geometry. The CNC machining department then produces the tool with high precision, ready for trials and production.
Robust materials and modern technologies
We tailor mold materials to the project — using cast iron or structural steel for tool longevity and stability. Where feasible we apply integrated metallic cores and hardened cores to boost rigidity and allow accurate reproduction of complex internal features. Casting in permanent molds ensures an exceptional surface finish, essential for components requiring smooth surfaces and an aesthetic appearance.
Accuracy, repeatability and process efficiency
This is a faster, more efficient manufacturing route that shortens lead time and minimises risk of casting defects such as cracks or porosity. With modern technologies and materials, our tools handle the most demanding projects, enabling aluminium/aluminum castings with high precision and durability. Every production stage is closely monitored so our gravity‑die castings meet strict quality standards and customer expectations for strength and service life.
Melting and pouring — a precise process in our foundry
Charge control and advanced melt‑treatment technologies
Charge material has a decisive impact on melt quality. We therefore give special attention to correct storage and preparation to avoid contamination, moisture and alloy mix‑ups that could affect the microstructure and mechanical properties of finished castings. Each step of storage and charge preparation is monitored to ensure optimal parameters before melting — the foundation of precise, durable permanent‑mold castings that meet rigorous industrial standards.
We use modern electric melting furnaces for aluminium/aluminum and other non‑ferrous alloys, delivering efficient and environmentally responsible operation. High thermal efficiency and precise temperature control produce a homogeneous melt that ensures repeatability and premium quality in gravity‑die castings while optimising energy use.
Pouring is carried out under controlled conditions to achieve smooth surface finish and eliminate typical casting defects such as gas porosity and non‑metallic inclusions. With precise dosing of molten metal and temperature matched to the alloy, we secure process stability and maximum repeatability across every production batch.
Charge materials and melt preparation for casting
Guaranteed charge cleanliness and alloy quality control
Robust materials and modern technologies
We use only certified charge materials whose chemical composition closely matches customer requirements. Alloying additions are dosed only when specified by the client’s technical parameters. This guarantees high quality and repeatability of the casting alloys, directly translating into excellent mechanical properties and appearance of the final parts.
We do not use aluminium/aluminum scrap from external sources because chemical cleanliness and stable alloy quality are a priority. In exceptional cases, to improve process economics, we introduce our own internal returns — production rejects and runner systems. These materials are strictly selected and prepared so their chemistry fits the required standard. Each charge is precisely controlled and analysed for elemental content to keep alloy consistency and ensure maximum casting quality.
Refining and modification — enhancing molten‑metal properties
To achieve top melt quality we apply advanced refining and modification (degassing and fluxing, grain refinement), which remove unwanted gases and inclusions and optimise the alloy’s microstructure. This directly improves tensile strength, hardness and crack resistance before the metal enters the permanent mold.
Our modern quality‑control methods provide full monitoring at each stage to meet the most demanding requirements of the automotive, construction and machinery industries. We regularly perform chemical analyses and laboratory tests so every melt poured in our foundry delivers durable, precise permanent‑mold castings of the highest class.
Mold temperature control in permanent mold casting
Heat measurement — the key to repeatable casting quality
We carefully control mold temperature to ensure high quality and precision. Using modern heat‑measurement equipment, we continuously monitor mold temperature before pouring. This allows us to adjust process parameters to the alloy and the casting’s technical requirements.
Regular temperature control optimises solidification, reducing the risk of defects such as gas porosity, shrinkage and micro‑cracking. Correct mold temperature ensures uniform microstructure, superior surface finish and accurate detail reproduction — the basis for dimensional and mechanical repeatability of every casting.
Charge materials and melt preparation
Which aluminium alloys do we use for pressure die casting?
| Aluminium Alloy | Main Alloying Elements | Properties | Typical Applications |
|---|---|---|---|
| EN AC-42000 | Silicon (6–8%), Magnesium (0.2–0.5%) | Good fluidity, high corrosion resistance, medium strength | Automotive parts, engine housings, machinery components |
| EN AC-46200 | Silicon (9–11%), Copper (2–4%) | High strength, very good castability, moderate corrosion resistance | Engine blocks, structural parts, fittings |
| EN AC-46500 | Silicon (10–13%), Magnesium (0.05–0.5%) | Excellent castability, good corrosion resistance, stable dimensions | Electronics enclosures, automotive components, home appliances |
| EN AC-47100 | Silicon (11–13%), Copper (1.0–2.5%) | Very good fluidity, high mechanical strength | Automotive parts, engine components, electrical equipment |
| EN AC-51300 | Magnesium (4.5–5.5%), Silicon (0.4–0.8%) | Excellent corrosion resistance, high tensile strength | Automotive, structural and engineering components |
Frequently Asked Questions — FAQ
Most common questions about permanent mold (gravity die) casting
How does permanent mold casting differ from other casting methods?
Permanent mold (gravity die) casting uses metal moulds/molds, which deliver greater precision and repeatability than sand casting and some other processes. As a result, castings have superior surface quality, require less secondary machining and are more durable. The method is especially effective for serial production where dimensional accuracy and stability are critical.
Which materials can be poured in permanent molds?
The most common choice is aluminium/aluminum alloys, but bronze, brass and zinc alloys are also possible. The selection depends on the target application and requirements for strength, corrosion resistance and thermal conductivity.
What are the main advantages of permanent mold (gravity die) casting?
High precision and dimensional repeatability.
Excellent surface finish that reduces the need for additional machining.
Shorter production time compared to traditional methods.
Cost‑effective serial production with lower unit cost.
Better quality control and improved casting durability.
Which industries use permanent‑mold castings?
Permanent‑mold castings are widely used in automotive, aerospace, electronics, construction and general machinery. Typical applications include engine components, electronics housings, industrial fittings, decorative and structural parts.
What is the weight range of our permanent‑mold castings?
We produce castings from 0.1 kg to 50 kg, covering both small precision details and larger structural components. The final solution depends on technical specifications and the requirements of your industry.
Is short‑run production of permanent‑mold castings possible?
Yes. In addition to serial production, we deliver short runs and prototypes. Feasibility is agreed individually, depending on part complexity, quantity and tooling availability. Manual pouring of metal molds lets us produce non‑standard castings that meet unique technical requirements.
How do we prepare molds for permanent mold casting?
All molds are designed and manufactured in‑house using advanced 3D software and CNC technology. Depending on production needs, we use cast iron or structural steel to ensure tool durability and precise reproduction of details.
How do we ensure casting quality?
Each stage is controlled for alloy chemistry, melting and pouring temperatures and finished‑part quality. We also use melt refining and modification to remove impurities and improve mechanical properties of the castings.
How much do permanent‑mold castings cost?
Cost depends on part size and complexity, alloy selection and order volume. In serial production the unit cost is lower, making this method particularly attractive for industrial customers.
How to place an order with our foundry?
Contact us by phone or email for a quotation. Send technical specifications and, if possible, a drawing or 3D model. Our engineers will propose the best process route, lead time and unit‑cost scenarios for your application.