Material
Die Casting Alloys: Expert Material Selection for Optimal Performance
Engineering precision components with the perfect material for your application
The right material selection is critical to your product's performance, cost-effectiveness, and competitive edge. Our materials expertise helps you navigate complex engineering decisions with confidence.
Our Materials Services
- Material Testing & Analysis
- Custom Alloy Development
- Material Selection Consulting
- Performance Optimization
Material Selection Excellence
Importance of Selection
How proper alloy selection impacts product performance, cost & market competitiveness
Materials Expertise
Our engineering team combines materials science backgrounds with state-of-the-art testing equipment
Selection Process
We implement a systematic material selection methodology based on thorough requirement analysis
Material Innovation
We specialize in special alloy development and custom formulations for non-standard requirements
Recent Case Study
Our material optimization helped a startup reduce component weight by 30% and manufacturing cost by 22%, accelerating their time to market by 45 days.
Materials Library
Zinc Alloy Die Casting
Precision zinc components with fine details
Various surface finishing options for zinc alloys
Zinc Alloy Properties & Advantages
Superior Casting Characteristics
- Exceptional fluidity for intricate details
- Low melting point (380-390°C)
- Fast cycle times (15-20 seconds)
- Longest die life of all die cast metals
- Excellent thin wall capabilities (0.5mm)
Mechanical & Physical Properties
- Good strength-to-weight ratio (6.6 g/cm³)
- Superior impact resistance
- Excellent dimensional stability
- Good vibration damping properties
- Moderate electrical and thermal conductivity
Finishing & Aesthetic Qualities
- Excellent surface finish quality
- Superior plating receptivity
- Wide range of coating options
- Corrosion resistance with proper finishing
- Ideal for decorative applications
Common Zinc Alloy Types
| Alloy Type | Composition | Properties | Typical Applications |
|---|---|---|---|
| Zamak 3 (ASTM AG40A) | 96% Zn, 4% Al, 0.04% Mg, 0.05% Cu |
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| Zamak 5 (ASTM AC41A) | 95% Zn, 4% Al, 0.04% Mg, 1% Cu |
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| Zamak 2 (ASTM AC43A) | 95% Zn, 4% Al, 0.04% Mg, 3% Cu |
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| ZA-8 | 89% Zn, 8.4% Al, 1.1% Cu, 0.02% Mg |
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Zinc Alloy Design Considerations
Design Optimization
- Minimum wall thickness: 0.5mm (thinner than aluminum)
- Draft angles: 1-1.5° possible (less than other metals)
- Tight tolerances achievable (±0.05mm for small dimensions)
- Excellent for intricate geometries and fine details
- Cross-section variations should be gradual
- Design for uniform cooling
Design for Post-Processing
- Excellent substrate for plating operations
- Design with finishing requirements in mind
- Avoid sharp corners for better coating adhesion
- Consider parting line placement for aesthetic surfaces
- Design for secondary operations (threading, machining)
- Part marking and identification areas
Design Note: Zinc alloys can experience creep under sustained loading at elevated temperatures. For structural components under constant stress, proper alloy selection and design considerations are critical.
Industry Applications
Consumer Electronics
- Smartphone frames and components
- Camera bodies and lens housings
- Audio equipment enclosures
- Gaming controllers and accessories
Why zinc: Excellent EMI shielding, thin walls, and premium feel with decorative finishes
Automotive
- Door lock mechanisms
- Windshield wiper components
- Interior trim pieces
- Decorative badges and emblems
Why zinc: Cost-effective, precision design, and good dimensional stability with vibration damping
Hardware & Construction
- Door and window hardware
- Cabinet pulls and knobs
- Plumbing fixtures
- Decorative architectural elements
Why zinc: Superior surface finish quality, good corrosion resistance when plated, and design versatility
Ready to enhance your product with zinc die casting?
Our zinc die casting specialists can help you leverage the advantages of zinc alloys for your specific application.
Magnesium Alloy Die Casting
Lightweight magnesium alloy components
Advanced automotive magnesium applications
Magnesium Alloy Properties & Advantages
Exceptional Weight Reduction
- Lightest structural metal (1.8 g/cm³)
- 35% lighter than aluminum
- 78% lighter than steel
- Excellent strength-to-weight ratio
- Enables significant weight savings
Mechanical Properties
- Good tensile strength (230-250 MPa)
- High specific stiffness
- Superior vibration damping
- Excellent impact resistance
- Good fatigue resistance
Additional Benefits
- Superior EMI/RFI shielding
- Good thermal conductivity
- Non-magnetic properties
- Excellent machinability
- 100% recyclable material
Common Magnesium Alloy Types
| Alloy Type | Composition | Properties | Typical Applications |
|---|---|---|---|
| AZ91D | 9% Al, 0.7% Zn, 0.3% Mn, Mg balance |
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| AZ91D | 9% Al, 0.7% Zn, 0.3% Mn, Mg balance |
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| AM50A | 5% Al, 0.3% Mn, Mg balance |
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| AM60B | 6% Al, 0.3% Mn, Mg balance |
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| AE44 | 4% Al, 4% RE (rare earth), Mg balance |
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Magnesium Alloy Design Considerations
Design Guidelines
- Minimum wall thickness: 1.5mm (typical)
- Draft angles: 2-3° recommended
- Generous fillets and radii (2-3× wall thickness)
- Design for uniform wall thickness
- Avoid sharp corners and abrupt transitions
- Consider gate and runner placement
Process Considerations
- Hot chamber and cold chamber processes
- Special safety considerations for molten Mg
- Proper venting for air entrapment prevention
- Surface treatments often required
- Design for optimal flow pattern
- Optimize for minimal porosity
Safety Note: Magnesium die casting requires specific safety protocols during manufacturing due to the flammability of magnesium at high temperatures. Our facilities implement specialized safety measures to ensure secure production.
Industry Applications
Automotive
- Steering wheel cores
- Instrument panel structures
- Seat frames
- Transmission housings
- Engine components
Why magnesium: Significant weight reduction, vibration damping, and design flexibility
Electronics & Telecommunications
- Laptop and tablet housings
- Camera bodies
- Smartphone frames
- EMI/RFI shielding enclosures
- Handheld device components
Why magnesium: Light weight, excellent EMI shielding, and superior heat dissipation
Aerospace & Defense
- Drone components
- Aircraft seat frames
- Portable equipment cases
- Gearboxes
- Avionics housings
Why magnesium: Ultra-lightweight, high stiffness, and excellent vibration damping properties
Interested in magnesium die casting for your project?
Our magnesium specialists can help you evaluate if this exceptional lightweight material is right for your application.
Aluminum Alloy Die Casting
Precision aluminum die cast components
Automotive aluminum die casting components
Aluminum Alloy Properties & Advantages
Key Physical Properties
- Low density (2.7 g/cm³)
- Good strength-to-weight ratio
- High thermal conductivity
- Excellent corrosion resistance
- Non-magnetic material
Mechanical Advantages
- Moderate to high tensile strength
- Good dimensional stability
- Excellent fatigue strength
- Good high-temperature performance
- Superior pressure tightness
Processing Benefits
- Excellent castability
- Good machinability
- Various surface finishing options
- Recyclable material
- Cost-effective for mass production
Common Aluminum Die Casting Alloys
| Alloy Type | Composition | Properties | Typical Applications |
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| A380 | 8.5% Si, 3.5% Cu, Al balance |
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| A383 | 10.5% Si, 2.5% Cu, Al balance |
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| ADC12 (Japanese) | 10.5% Si, 2.5% Cu, Al balance |
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| A413 | 12% Si, Al balance |
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Aluminum Die Casting Design Considerations
Design Guidelines
- Minimum wall thickness: 0.8-2.5mm
- Draft angles: 1-3° recommended
- Optimal radii: at least wall thickness × 1.5
- Uniform wall thickness recommended
- Consider shrinkage rate: 0.5-0.7%
- Design with ejection in mind
Process Considerations
- Cold chamber process typically used
- Optimal gating system design
- Proper venting for air entrapment
- Parting line placement
- Die temperature control
- Post-processing requirements
Design Tip: For pressure-tight aluminum die castings, consider secondary impregnation processes. These can effectively seal micro-porosity in critical applications such as fluid-containing components or pressure vessels.
Industry Applications
Automotive
- Engine blocks and components
- Transmission cases
- Cylinder heads
- Intake manifolds
- Suspension components
- EV battery housings
Why aluminum: Weight reduction, thermal management, dimensional stability
Electronics & Telecommunications
- Heat sinks
- LED lighting housings
- Telecommunication components
- Computer chassis
- Server rack components
Why aluminum: Excellent heat dissipation, EMI shielding, corrosion resistance
Industrial Applications
- Pneumatic valve bodies
- Hydraulic components
- Pump housings
- Industrial machinery parts
- Robotic components
Why aluminum: Pressure tightness, good machinability, dimensional stability
Need aluminum die casting for your project?
Our engineering team can help you select the right aluminum alloy and design for manufacturability.
Copper Alloy Die Casting
High-conductivity copper alloy die cast components
Brass die castings for decorative and functional applications
Copper Alloy Properties & Advantages
Key Physical Properties
- High density (8.4-8.9 g/cm³)
- High melting point (900-1050°C)
- Excellent electrical conductivity
- Superior thermal conductivity
- Inherent antimicrobial properties
Mechanical Advantages
- High tensile strength
- Excellent wear resistance
- Good corrosion resistance
- Non-sparking properties
- Self-lubricating capabilities
Processing Benefits
- Excellent castability
- Suitable for cold chamber process
- Good machining characteristics
- Wide range of finish options
- Superior final surface quality
Common Copper Die Casting Alloys
| Alloy Type | Composition | Properties | Typical Applications |
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| Yellow Brass (C85800) | 57% Cu, 40% Zn, 3% other |
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| Silicon Brass (C87500) | 82% Cu, 14% Zn, 4% Si |
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| Silicon Bronze (C87600) | 88% Cu, 4% Zn, 4% Si, 4% other |
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| High-Copper Alloy (C96400) | 98% Cu, 2% other |
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Copper Die Casting Design Considerations
Design Guidelines
- Minimum wall thickness: 1.0-1.5mm
- Draft angles: 1-3° recommended
- Optimal radii: 0.5mm minimum
- Consider higher shrinkage: 1.5-2.0%
- Avoid sharp corners (stress concentration)
- Design for optimal metal flow
Process Considerations
- Cold chamber process required
- Higher die temperatures needed
- Longer cycle times than aluminum/zinc
- Special die materials to prevent erosion
- Specialized gating and venting design
- Proper thermal management critical
Design Tip: When designing copper alloy die castings, prioritize uniform wall thickness to minimize hot spots and ensure proper solidification. Consider the higher thermal expansion and shrinkage rates compared to aluminum alloys when establishing tolerances.
Industry Applications
Plumbing & Fluid Handling
- Faucets and fixtures
- Valves and regulators
- Pump components
- Pipe fittings
- Water meters
Why copper: Corrosion resistance, biostatic properties, pressure tightness
Electrical & Electronics
- Electrical connectors
- Heat sinks
- Terminal blocks
- Switch components
- Circuit breaker parts
Why copper: Superior electrical conductivity, excellent thermal management, reliability
Marine & Harsh Environments
- Marine hardware
- Propeller components
- Underwater equipment
- Chemical processing parts
- Corrosion-resistant fittings
Why copper: Exceptional corrosion resistance, durability in harsh environments, long service life
Need copper alloy die casting for your project?
Our engineering team specializes in high-conductivity, corrosion-resistant copper components with precision tolerances.
Material Solutions for Innovators & Startups
We understand the unique challenges startups face when bringing innovative products to market. Our tailored material solutions ensure continuity from prototype to volume production.
Material continuity from prototype to mass production
Maintain consistent quality and performance as you scale your production volumes.
Cost optimization strategies
Specialized approaches for small batches and frequent iterations without breaking your budget.
Investor-ready material selection
Make the right impression with materials that showcase your product's full potential during demonstrations.
Bringing innovative materials to startups worldwide
Startup Success Story
A robotics startup needed materials that could withstand rigorous testing while remaining cost-effective during their R&D phase. We developed a custom material solution that reduced their prototype costs by 35%.
Startup Die Casting Guide
Everything you need to know about die casting for early-stage hardware products.
Small-Batch Solutions
Discover specialized manufacturing approaches designed specifically for startups with limited initial production needs.
Material Performance Comparison Tool
Make informed decisions with our comprehensive die casting alloy comparison and selection system
Interactive Material Selector
Input your specific requirements and let our system recommend the most suitable die casting alloys for your application.
Alloy Performance Comparison
Comprehensive comparison of performance parameters for major die casting alloys.
| Alloy | Tensile Strength | Density | Max Temp | Cost Index |
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| A380 (Al) | 330 MPa | 2.76 g/cm³ | 180°C | |
| Zamak 3 | 283 MPa | 6.6 g/cm³ | 95°C | |
| Magnesium AZ91D | 230 MPa | 1.81 g/cm³ | 135°C |
Cost-Benefit Analysis
Evaluate the long-term economic impact of your material selection decisions.
Long-term Considerations:
- Processing difficulty and equipment requirements
- Expected service life under operational conditions
- Maintenance and replacement frequency
- End-of-life recyclability and environmental impact
Application Case Library
Explore real-world material selection success stories categorized by industry.
A major automotive manufacturer reduced component weight by 32% while maintaining structural integrity by switching from cast iron to A380 aluminum alloy for transmission housings.
Engine block redesign using ADC12 aluminum alloy with specialized heat treatment resulted in 15% better thermal performance and extended service life.
Interior structural brackets redesigned using Zamak 3 zinc alloy achieved 28% cost reduction while meeting all performance requirements.
Ready to Find Your Optimal Material Solution?
Our material performance comparison tool helps engineering teams make data-driven decisions that balance performance requirements with economic considerations.
Designed for engineers by engineers. Optimized for RoboTech and similar precision applications.
Frequently Asked Questions
Get answers to common questions about our die casting processes, materials, and capabilities.
When selecting a die casting alloy, consider these key factors:
- Mechanical requirements: Consider strength, hardness, and impact resistance needed.
- Weight considerations: Magnesium is lightest, followed by aluminum, then zinc.
- Dimensional accuracy: Zinc typically offers the best precision for intricate parts.
- Thermal properties: Different alloys have varying heat dissipation capabilities.
- Cost factors: Material costs, tooling requirements, and production volumes affect total cost.
- Surface finish requirements: Different alloys offer varying surface qualities and finishing options.
Our engineering team can help evaluate these factors for your specific application.
Lead times vary depending on complexity, but generally follow these timelines:
- Tool design: 1-3 weeks depending on complexity
- Tool manufacturing: 4-8 weeks for standard tools
- Tool sampling and validation: 1-2 weeks
- Production lead time: 2-6 weeks after tool approval
Expedited timelines may be available for critical projects. Complex or large tools may require additional time.
Our die casting capabilities cover a wide range of part sizes:
- Minimum size: Parts as small as 0.5 in² (3.2 cm²)
- Maximum size: Up to 36 in x 42 in (91 cm x 107 cm) for aluminum
- Weight range: From a few grams up to 25 kg (55 lbs)
Size capabilities may vary by alloy type and specific part geometry. Our engineering team can provide guidance on feasibility for your specific requirements.
Each manufacturing process has distinct advantages:
| Factor | Die Casting | CNC Machining | Injection Molding |
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| Production Volume | Medium to high | Low to medium | Medium to high |
| Material Options | Metal alloys | Wide range | Polymers |
| Tooling Cost | Higher initial | Low to none | Medium |
| Per-Part Cost | Low at volume | Higher | Very low at volume |
Die casting excels for metal parts needed in medium to high volumes where strength, precision, and thermal properties are important.
Optimizing your design for die casting can improve quality and reduce costs:
- Uniform wall thickness: Maintain consistent thickness to prevent cooling issues
- Draft angles: Include 1-3° draft on vertical surfaces to facilitate part ejection
- Fillets and radii: Avoid sharp corners to improve metal flow and structural integrity
- Rib design: Keep rib thickness to 60% or less of the adjoining wall thickness
- Parting line considerations: Strategic placement can simplify tooling and reduce cost
Our design for manufacturing (DFM) review process helps identify and address any design challenges before tooling production.
Still have questions? Our technical team is here to help.
