Medical Die Casting & Precision Manufacturing for Healthcare OEMs

IEC Mould is a precision die casting and machining manufacturer supporting global medical device OEMs with high-performance aluminum, magnesium, and zinc components. We work closely with engineering, procurement, and quality teams from early feasibility and DFM evaluation through tooling, mass production, CNC machining, finishing, and assembly.

Medical devices demand high dimensional accuracy, lightweight construction, corrosion resistance, consistent finishes, and reliable documentation support—capabilities IEC Mould delivers through controlled manufacturing processes and strict quality management systems certified to ISO 9001 and IATF 16949.

Why Medical Devices Need Metal Casting Components

Medical devices and surgical equipment require compact, lightweight, durable, and corrosion-resistant metal components that can withstand continuous use, cleaning cycles, and environmental exposure.

For these reasons, aluminum and zinc die casting has become a preferred process for producing housings, frames, brackets, and structural elements used in diagnostic equipment, monitoring systems, surgical instruments, and portable medical devices.

Compared with plastics or stamped metal, die-cast medical parts offer:

Higher structural rigidity
Improved dimensional stability
Superior heat dissipation
Better shielding against EMI/RFI
Longer component lifespan
High-volume consistency with lower unit cost

Die casting enables medical device manufacturers to combine functional performance with compact exterior design—critical for modern portable, digital, and handheld medical systems.

Engineering Challenges & Medical Industry Pain Points

Medical device OEMs and contract manufacturers typically face the following engineering and regulatory challenges during product development and mass production:

Pain Point	Impact on Medical Device Production	Engineering Solution from IEC
Tight tolerances for assembly	Misalignment, leakage, vibration, poor sealing, non-conforming assemblies	DFM tolerance prediction + precision HPDC + multi-axis CNC finishing ensures stable fits down to ±0.01 mm
Complex housing geometries	Higher tooling cost, machining time, and reject rates	Moldflow-driven tooling + optimized gate/runner/venting + multi-slide inserts reduce complexity and machining dependency
EMI/RFI shielding requirements	Signal distortion, reduced sensor accuracy, failed certification	Aluminum die casting + conductive surface finishing + controlled wall thickness improves shielding effectiveness
Lightweight & compact design	Structural integrity + thermal dissipation trade-offs	Material selection + ribbing + topology-informed HPDC design improves stiffness-to-weight ratio
Cosmetic surface requirements	Increased rejection during final QC	Integrated finishing stack (brushing, blasting, coating, anodizing) delivers Class-A cosmetic surfaces
Quality & traceability compliance	Higher documentation and regulatory burden	ISO 9001 QMS + full traceability + PPAP + CPK data + 3D CMM reports reduce compliance risks

How We Solve These Pain Points for Medical Casting Parts

IEC’s medical die casting solutions are built to support both development speed and compliance-critical manufacturing, including:

Early DFM for Medical Metal Parts

Scope: Early manufacturability & tolerance planning

Key Engineering Actions:

Wall thickness optimization (shielding vs weight trade-offs)
Ribbing, bosses & datum structure for rigidity
Undercut & deep cavity moldability review
CNC allowance & datum reference planning

Outcome: Fewer late-stage tooling modifications & faster validation cycles

Moldflow & Tooling Integration

Scope: Tooling accuracy & porosity control

Key Engineering Actions:

Gate and runner design for balanced flow
Venting path design to reduce gas traps
Thermal balance for dimensional stability
Ejection & cooling layout for cycle stability

Outcome: Improved yield, better surface integrity, reduced porosity — critical for medical housings

Die Casting + CNC Hybrid Manufacturing

Scope: Net-shape + precision finishing

Capabilities:

High pressure die casting (HPDC) for structural housings
3-axis, 4-axis, 5-axis CNC for precision interfaces
Controlled datum features & sealing surfaces

Outcome: CNC used only where needed, reducing cost without compromising precision

Finishing & Cosmetic Control Stack

Scope: Surface quality & durability consistency

Processes:

Bead blasting
Brushing
Powder coating
Liquid painting
Anodizing (Aluminum)
Conductive finishing (optional)

Outcome: Achieves consumer-grade cosmetics + medical-grade durability simultaneously

Quality, Inspection & Documentation

Scope: Regulatory compliance & traceability readiness

Provided Deliverables:

3D CMM dimensional reports
Material test certifications (Incoming & outgoing)
PPAP, FAI, CP, PFMEA, Control Plan
RoHS / REACH compliance statements

Outcome: Supports medical OEM audits & compliance documentation with confidence

Low-variance Mass Production Control

Scope: Scaling from prototype to stable series runs

Manufacturing Control Measures:

SPC (Statistical Process Control)
APQP for tooling + process intro
CPK capability tracking for key dimensions
Lot traceability with serialization options
Preventive maintenance on dies & CNC
COSMETIC AQL sampling for visible housings

Outcome:Stable long-term supply with minimized variability & reject rates

Metal Die Casting Material Options for Medical Device Components

Material selection affects strength, mass, biocompatibility, cost, corrosion resistance, and manufacturability. We support multiple materials for medical parts:

Aluminum Alloys Die Casting

Aluminum is widely used in housings, frameworks, and diagnostic devices requiring EMI shielding. Common alloys for die casting or machining include:

ADC12 / A380 (excellent castability)
A360 (better corrosion resistance)
6061 / 6063 (machined or extrusion-grade)
AlSi10Mg series (low porosity for structural parts)

Advantages:

Lightweight with good strength
Corrosion resistant
Good machining performance
Compatible with anodizing
Non-magnetic (MRI-friendly)

Magnesium Alloys Die Casting

Common alloy:

AZ91D

Advantages:

30–35% lighter than aluminum
High specific strength
Good damping characteristics (useful for handheld devices)

Used for surgical handheld instruments and portable devices.

Zinc Alloys Die Casting

Common alloys, commonly used in dental tools, knobs, ergonomic interfaces, and mechanical linkages.

Zamak 3 / Zamak 5

Advantages:

Excellent dimensional accuracy
Thin-wall capability
Superior surface finish for cosmetic parts
Ideal for complex small components and mechanisms

Common Medical Components Manufactured by Die Casting & CNC

We supply die cast and machined components for a wide range of medical applications, including:

Surgical & Operating Room Equipment

Surgical instrument housings
Adjustable mechanism brackets
Surgical lighting system components
Tool handles and ergonomic grips
Sterilization tray metal fixtures

Healthcare Electronics & Monitoring Devices

Patient monitor housings
PCB mounting frames
ECG/EEG equipment enclosures
Power module heat-sink components
Battery & charger housings

Rehabilitation & Patient Mobility Devices

Wheelchair and mobility hardware
Mechanical adjustment joints
Structural supports and frames
Custom mounting and interface parts

Hospital Hardware & Infrastructure

Bed mechanisms and control housings
Medical cart frames and brackets
Pump and valve components
Industrial-grade connectors

Diagnostic and Imaging Equipment

MRI and CT structural brackets
Ultrasound device aluminum housings
X-ray detector frames
Sensor mounting fixtures
RF shielding enclosures

Dental Devices & Dental Lab Equipment

Dental chair structural components
Handpiece housings and sleeves
Dental imaging brackets
Polishing & suction system housings

These product categories often require repeatable long-term manufacturing, material compliance, and revision-controlled documentation — areas where IEC Mould maintains strong capability.

Engineering DFM & Moldflow Support for Medical Components

Medical components often involve thin walls, functional geometries, and aesthetic expectations. Early collaboration reduces cost and prevents engineering failures. Our DFM engineering support includes:

Geometry Feasibility Review

We evaluate:

Draft angles
Undercuts
Thin walls
Bosses and ribs
Sharp corners or transitions
Gating and venting paths

Moldflow & Simulation

Simulation detects:

Fill imbalance
Cold shuts
Air entrapment
Weld lines
Porosity concentration
Hot spots and shrinkage

Assembly & Integration Support

We ensure compatibility with:

Plastic housings
Bearings & shafts
Sensors & electronics
O-ring grooves & sealing paths

Design-to-Cost Optimization

We propose changes that reduce:

Cycle time
Material usage
Secondary machining
Tool complexity

Tooling & Die Casting Manufacturing Process for Medical Devices

IEC Mould integrates tooling, die casting, machining, finishing, assembly, and inspection into a coherent manufacturing process suitable for long-term production.

Standard Manufacturing Workflow

RFQ & drawing review
DFM & feasibility confirmation
Moldflow analysis
Tooling design
Tool steel selection & fabrication
Mold trials

Dimensional inspection

HPDC mass production
CNC machining & tapping
Deburring & cleaning
Surface finishing
Final inspection & FAI reports
Packaging & documentation
Batch traceability & shipment

Tooling Capabilities

Multi-slide tooling
Thin-wall tooling
Hot runner & vacuum venting
Rapid cooling circuits
Cavity pressure monitoring (when required)
EDM, high-speed milling, and precision grinding

Die Casting Capabilities

HPDC from 80T to 1250T
Vacuum assist for porosity reduction
Water-cooling for dimensional stability
Process control via temperature & shot monitoring

Secondary Operations

CNC machining (3/4/5-axis)
Turning
Threading (M, UNC/UNF, MJ)
Reaming & tapping
Deburring & polishing
Helicoil insert installation

CNC Machining for Medical Components

CNC machining enhances precision for features that are not achievable by casting alone.

Machining Capabilities

3-axis, 4-axis, and 5-axis milling
Swiss-type turning for small shafts & pins
Micro-hole drilling
Tapping and threading
Helical milling
±0.01 mm tolerance control (feature-dependent)

Machinable Features for Medical Parts

Face & shoulder milling
Dynamic tool paths for complex contours
O-ring grooves & sealing features
Counterbores & countersinks
Chamfers & radius profiles
Orthopedic slot features
Precision bore alignment

Burr-Free & Clean Surface Control

Automated deburring
Media tumbling
Brush polishing
Electro-polishing (for stainless steel)
Edge-break control
Particle-free cleaning

Documentation & Validation

CMM dimensional reports
First Article Inspection (FAI)
PPAP if required
Traceability records
Surface roughness measurement
Material certificates

General Tolerance Guideline for Medical Die Casting Parts

Below are typical achievable tolerances (feature-dependent):

Feature	Tolerance Capability
Linear dimension	±0.05 mm – ±0.10 mm (machined ±0.01 mm)
Hole diameter (machined)	±0.01 – ±0.03 mm
Flatness	≤0.02 – 0.05 mm
Roundness	≤0.01 – 0.03 mm
Thread accuracy	6H / 6g / UNC / UNF / MJ
Surface roughness	Ra 0.8 – 1.6 μm (machined)

Surface Finishing for Medical Components

Surface finishing enhances corrosion resistance, cosmetic quality, ergonomics, and cleanability.

Anodizing (Type II & III)

Suitable for aluminum housings and handles
Improves corrosion resistance
Available in medical grade clear, black, etc.

Electropolishing (Stainless Steel)

Improves corrosion resistance
Reduces surface roughness
Suitable for surgical tools

Liquid Painting & Powder Coating

RoHS compliant coating systems
Uniform cosmetic appearance
Chemical-resistant options for cleaning agents

Passivation

Applied to stainless steel to remove free iron
Increases corrosion resistance

Electroless Nickel Plating

Cosmetic or functional
Used in hospital hardware and dental equipment

Sandblasting / Bead blasting

Satin texture for ergonomic surfaces
Improves coating adhesion

Brushing

Applied to aluminum housings after machining
Controls surface roughness and visual uniformity
Used on visible panels to reduce cosmetic variation

Chromate conversion

Applied to aluminum die cast components
Maintains electrical conductivity and grounding
Used for corrosion protection under RoHS compliance

Laser marking

Permanent marking on aluminum and zinc parts
No inks or chemicals, no effect on tolerances
Supports serial numbers and traceability

Case Studies (Typical Applications)

Below are representative examples showing how engineering collaboration reduces risk and cost.

Case A: Ultrasound Housing Weight Reduction

Objective: Reduce weight for improved portability
Material: Aluminum alloy
Method: HPDC + thin-wall optimization
Result: 22% weight reduction + improved heat dissipation

Case B: Patient Monitor Chassis Alignment

Objective: Achieve precise alignment for PCB mounting
Method: Casting + CNC machining on critical features
Result: ±0.02 mm hole alignment tolerance achieved

Case C: Dental Imaging Bracket Shielding

Objective: Provide EMI shielding for digital imaging sensors
Material: Magnesium alloy
Finish: Conductive coating
Outcome: Reduced electronic interference & stable performance

Start Your Medical Device Project

IEC Mould supports medical OEMs from early engineering to mass production. To get started, simply send:

2D/3D files
Estimated annual volumes
Key requirements

Our team will provide a fast quotation with cost, lead time, and technical feedback.