Aluminum foundry · Janikowo near Poznań
Die casting – specialized aluminum castings
Aluminum high-pressure die castings in series of up to 100,000 pcs per year. We design the molds in CAD/CAM and make them on our own CNC machines, and cast on an automated line with control of temperature, pressure and cycle time.
- Tolerances
- ±0,1 mm
- often achievable – depending on part geometry
- Molds
- CAD/CAM + CNC
- designed and made in our plant
- Series
- up to 100,000 pcs per year
- also prototypes and specialized runs
- Quality
- ISO 9001 · 14001
- TÜV Rheinland certificates
Aluminum high-pressure die casting foundry
We specialize in aluminum high-pressure die casting technology
Looking for a proven partner for the production of precision aluminum components? You've come to the right place – we offer comprehensive high-pressure die casting services using modern machines and certified molds. Our technology produces complex shapes with exceptional accuracy, making it well suited to the automotive, household appliance, electronics and industrial sectors. We guarantee not only high quality and durable castings, but also repeatability, short lead times and full technical support at every stage of our cooperation.
High-Pressure Die Casting at a Glance
High-pressure die casting is a process in which liquid metal is injected under high pressure into a steel mold – the die. It produces castings with high dimensional repeatability and a very good surface finish, often ready for assembly or light machining.
- Material
- aluminum alloys – the alloy is selected to suit the function of the part
- Tolerances
- often around ±0.1 mm – depending on part geometry
- Molds
- tool steel, conformal cooling channels, metal cores; CAD/CAM design with melt flow simulation
- Series
- up to 100,000 pcs per year – series production as well as short, specialized runs and prototypes
- Process
- automated line, real-time parameter monitoring, part traceability
- Industries
- automotive, household appliances, electronics, technical fittings, aerospace, industrial automation
Download · 4 pages
Process Data Sheet – High-Pressure Die Casting (PDF, 160 KB) (opens in a new window)
Process parameters, tool steel dies and a diagram of a cold-chamber machine.
01 · Technology
What exactly is the high-pressure die casting process and what sets it apart?
High-pressure die castings – fast, repeatable and tailored to your needs
High-pressure die casting is a technology that has changed the rules of mass production. In HPDC machines, molten metal is injected at high force into steel dies, where it solidifies in a precisely engineered shape. What does this deliver? Above all, outstanding accuracy and repeatability. In our aluminum die casting foundry we use only aluminum die casting dies designed for complex details and high surface quality. Modern high-pressure die casting reduces machining costs and shortens order lead times. It is a solution that any manufacturer will appreciate, regardless of industry.
High quality, precision and production flexibility
- We produce aluminum die castings in runs of up to 100,000 pcs per year – from prototypes and short runs to ongoing series production.
- We use casting process automation and an automated die casting line, which ensures consistent process parameters and quality of every part.
- We have shot sleeves of various capacities for die casting and match them to the requirements of each project.
- We provide die cooling, die refurbishment and die design in our in-house design shop.
With us, you get more than a die casting – we help you optimize the design for manufacturability, reduce part weight and select the ideal aluminum alloy for high-pressure die casting. Our experience is your gain. We operate in line with ISO requirements – as one of the die casting foundries with anISO certificate we ensure control at every stage of the process. And if you are up against deadlines, you will appreciate our approach to on-time delivery. Fast high-pressure die casting is our specialty. Efficient processes and automation allow us to maintain high quality even in large production volumes. We treat every order individually, adjusting casting parameters to the specific application and technical specification. This approach allows us to deliver both complex prototypes and series production for industry.
02 · Dies and applications
Applications of die castings in your industry
We are not limited to one industry – we produce castings wherever top workmanship and reliability matter.
We design and build die casting dies end to end – from the technical concept to a finished solution ready for series production. We use advanced CAD/CAM software and metal flow simulation, which helps us avoid errors in production and ensures maximum process efficiency. Our design department works closely with the CNC machiningdepartment, so every die is built with the precision needed for even the most demanding geometries.
Materials and solutions matched to industrial needs
We tailor aluminum die casting dies to the specifics of each order, using tool steel and alloys with enhanced thermal and wear resistance. Where needed, we integrate conformal cooling channels and metal cores, which extend die life and ensure repeatability in large production runs. Pressure die casting of metals delivers excellent surface quality without the need for extensive finishing, which is especially important in the automotive, home appliance and precision electronics industries.
Efficiency and repeatability in every production batch
High-pressure die casting technology enables fast, reliable production of large series of components with identical parameters. The process shortens lead times and minimizes scrap, partly by eliminating porosity and cracks. In our foundry we use modern high-pressure die casting machines that run fully automatically and are monitored in real time. As a result, we deliver high-precision, durable aluminum die castings that are successfully used in series production of automotive parts, home appliance components and technical elements.
Where our die castings are used
Automotive
Series-produced parts, housings and technical components.
Appliances and electronics
Housings and components with complex shapes.
Technical fittings and industrial automation
Leak-tight parts ready for assembly.
Lightweight, durable aluminum components.
03 · Production preparation
How is production of die castings prepared?
From die design to series production – everything under full control
CAD/CAM die design and toolroom
Everything starts with the design. In our foundry we use dedicated CAD/CAM systems that allow precise design of high-pressure die casting molds already at the stage of analyzing the customer's requirements. We take into account the part geometry, the planned number of cycles and the operating conditions of the mold. This minimizes the risk of later production downtime and costly rework. Each mold then goes to our toolroom, where it is made on CNC machines from top-grade materials.
High-pressure die casting of aluminum with control at every stage
In production we use only proven die casting materials, and the process is based on strict control of temperature, pressure and cycle time. Every batch of parts undergoes dimensional verification and structural testing, which ensures full repeatability and conformity with the technical documentation. We also use a traceability system that lets us identify the production parameters of any individual part at any time, which is essential for projects subject to certification or audit.
Our production process monitoring system eliminates the risk of errors, ensures consistent parameters and enables immediate detection of any deviations. As a result, the finished aluminum alloy die castings are durable, leak-tight and ready for further assembly or finishing – without additional rework. This is the level of quality expected by the most demanding customers in industries such as automotive, home appliances and industrial automation.
04 · Automation
Automation and technology supporting the high-pressure die casting process
A modern HPDC line guarantees repeatability and control over every detail
Modern aluminum high-pressure die casting is not only a matter of engineering knowledge, but above all of advanced technology. Our HPDC line was designed for maximum efficiency and reliability. Automatic control of the production cycle, precise alloy dosing and digital monitoring of parameters maintain constant conditions even in large production runs. This allows us to deliver precision die castings with identical physical properties and dimensions – without losses or rework. A high level of automation limits the human factor, which directly translates into lower costs and greater reliability.
One of the key elements supporting our process is the die cooling system, which keeps tool temperature stable and extends tool life. Regular refurbishment of dies in our plant allows them to be reused many times without loss of reproduction quality. This optimization of the molding cycle shortens the time between consecutive shots and increases overall production efficiency. By combining automation of the casting process with careful tool care, we ensure continuity of supply for our customers.
05 · Materials
Aluminum alloys for high-pressure die casting
Which aluminum alloys do we use?
We select the alloy based on the function of the part, the required strength and corrosion resistance. For high-pressure die casting, aluminum alloys with silicon and copper are used above all – examples are listed below (designations per PN-EN 1706). When quoting, we confirm which of them will work best for your part. We cast alloys EN AC-42000 and 51300 inpermanent molds.
| Aluminum alloy | Main alloying elements | Properties | Typical applications |
|---|---|---|---|
| EN AC-46200 | silicon (7.5–9.5%), copper (2.0–3.5%) | high strength, good castability, limited corrosion resistance | engine blocks, structural components, fittings |
| EN AC-46500 | silicon (8–11%), copper (2–4%), zinc (up to 3%) | very good castability and machinability, limited corrosion resistance | electronics housings, automotive parts, household appliances |
| EN AC-47100 | silicon (10.5–13.5%), copper (0.7–1.2%) | very good castability, even in thin walls; good pressure tightness | automotive parts, engine components, electrical equipment |
Chemical composition ranges are given for guidance only. The binding composition is the one specified in PN-EN 1706 and the material certificate.
06 · Choosing the Process
When to Choose High-Pressure Die Casting?
Comparison with Permanent Mold and Sand Casting
High-pressure die casting pays off for large production runs of parts with complex shapes and tight tolerances, where the die cost is spread over many pieces. For smaller runs where repeatable dimensions matter, permanent mold castingis a good fit, and for prototypes and large-size parts, sand casting. We will recommend the right process once we have seen your drawing.
- Permanent mold castingPermanent moldRuns with repeatable dimensions and a smooth surface finish. Reusable metal mold, medium mold cost; castings from 0.1 to 50 kg.
- Sand castingSand moldPrototypes, short runs, large and complex castings. Lowest mold cost, made from a pattern; castings from 1 to 100 kg.
- High-pressure die casting · this pageHPDC dieLarge runs of parts with complex shapes and tight tolerances, often ±0.1 mm. Highest die cost, spread over many pieces.
07 · Ordering
How to Order High-Pressure Die Castings?
From drawing to series delivery
Drawing and quotation data
2D drawing in PDF and 3D model in STEP format, material or alloy, quantity per run and per year, and machining and coating requirements.
Analysis and process selection
We check feasibility, select the process and alloy, and prepare the die concept already at the quotation stage.
Die or pattern
We design the die in CAD/CAM with metal flow simulation and make it from tool steel on CNC machines in our in-house tooling shop.
Casting, machining and finishing
We cast the parts, trim off the gating systems and, on request, CNC machine, grind and powder coat them.
Inspection and Delivery
Inspection according to the drawing and technical acceptance conditions within an ISO 9001 system, with delivery in Poland and abroad.
Need a part that is ready to assemble? We can complement the casting withCNC machining, grinding and polishing and powder coating.
08 · FAQ
Frequently Asked Questions – FAQ
Frequently asked questions about high-pressure die casting
High-pressure die casting (HPDC) is a manufacturing process in which molten metal is injected under high pressure into a steel mold, known as a die. This produces precise die castings with high dimensional repeatability and excellent surface quality. The technology allows parts to be produced that are ready for assembly or light machining almost straight out of the die.
The key benefits are fast cycle times, a low scrap rate, high repeatability, the ability to cast complex shapes, and shorter production lead times. The process is ideally suited to series production, where quality and on-time delivery are critical.
In our foundry we die cast aluminum alloys according to EN 1706. We select the alloy based on the function of the part, the required strength and corrosion resistance – sample alloys and their properties are listed in the table on this page.
Aluminum die castings are used in the automotive and electronics industries, household appliances, industrial valves and fittings, aerospace, and many other sectors. They are an excellent choice wherever light weight, strength and precision are required.
Yes, we handle both series production – up to 100,000 pcs per year – and short, specialized runs. We are flexible – we adapt the die casting process to the customer's requirements, even for small orders or prototypes.
We design aluminum die casting molds based on the customer's technical documentation. We then manufacture them in our own plant using CNC machines and specialized CAD/CAM software. This process ensures accurate reproduction of the geometry and a long mold life.
Yes. We design aluminum die casting molds in CAD/CAM with alloy flow simulation and manufacture them from tool steel on CNC machines in our in-house tooling department. We also provide mold cooling and refurbishment, so the mold maintains its reproduction quality over long production runs.
We maintain strict quality control at every stage – from automation of the casting process and pressure control to cooling and finishing. Parts undergo dimensional measurements, structural testing and strength tests. In addition, we refurbish die casting molds to ensure their durability and consistent production quality.
Thanks to the use of die casting machines and high-quality molds, very tight tolerances can be achieved – often in the range of ±0.1 mm, depending on the part geometry. This means the components can be used directly in precision mechanisms.
The price depends on the size and complexity of the part, the material used, the number of production cycles and the cost of preparing the mold. For larger volumes, the unit cost of a die casting drops significantly, which is why the process is ideal for series production.
Simply contact us via the form, by phone or by e-mail. Once we receive the technical specification and project parameters, we will prepare a customized quote. Our specialists will also advise which die casting technology will work best in your case.
The foundry is located in Poznań (ul. Gnieźnieńska 26, 62-006 Kobylnica). We supply die castings to companies throughout Poland and also deliver abroad.
Guides from the blog
More about high-pressure die casting
Contact and quote
Office open Mon–Fri 8:30 a.m.–4:30 p.m.
Contact
Die casting quote
Send a 2D drawing in PDF or a 3D model in STEP format, specify the aluminum alloy and the planned series size. In return, we will send you a proposed process, a mold concept and a quote.
Feel free to contact us by e-mail or phone
or visit us in person – you are welcome!
Janikowo near Poznań
62-006 Kobylnica
Office open Mon–Fri 8:30 a.m.–4:30 p.m.
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