Die Casting Services

There are two primary processes: hot chamber and cold chamber. Hot chamber suits low-melting-point metals such as zinc and offers fast cycle times. Cold chamber suits aluminum, keeping the molten metal separate from the injection system. Our engineering team recommends the right process at the feasibility review.

Pressure die casting forces molten metal into the mold under constant pressure until it solidifies, which fills the mold quickly and supports higher production volume. Gravity casting fills the mold from the bottom up using gravity. Pressure die casting costs more to set up, so it suits recurring volume rather than short runs.

We die cast aluminum alloys such as A380 and ADC12 and zinc alloys such as Zamak 3 and Zamak 5, with magnesium reviewed case by case. Aluminum is lightweight, conductive, and corrosion resistant; zinc has a low melting point that supports fast cycles and adds impact strength and ductility. Our engineering team confirms the best alloy for your part.

Die casting produces complex, dimensionally stable parts at high speed with thin walls and an excellent surface finish, often with little or no post-run machining. That makes it cost effective for high-volume non-ferrous production.

Die cast parts can ship as-cast or with secondary finishing including CNC machined surfaces, bead blasting, powder coating, painting, anodizing, chromate conversion coating, electroless nickel, and electroplating. The right finish depends on whether corrosion resistance, electrical conductivity, or cosmetic appearance is the priority, and our engineering team confirms it at the feasibility review.

Yes. Die casting produces near-net-shape parts, but features such as threaded holes, sealing faces, and tight mating surfaces are finished with secondary CNC machining. Combining casting with post-machining gives you the low per-unit cost of casting with the dimensional accuracy of machining where it matters.

Die casting carries high upfront tooling cost, so it is not economical for one-off parts or very low volumes, and the process is limited to non-ferrous alloys such as aluminum, zinc, and magnesium. It earns out on recurring production where the tooling cost amortizes across the run and the automated cycle drives the per-part price down.

Standard production lead time is 4 to 8 weeks, with tooling and first-article timing confirmed at the quote stage. Rush programs can be reviewed case by case.

Die casting carries high tooling cost, so it is built for recurring production rather than one-off parts. We will tell you at the quote stage whether your volume is a fit and recommend the most cost-effective process.

Inconsistent wall thickness. Non-uniform walls cause uneven fill and cooling during the casting cycle, leading to porosity, sink marks, and warpage. Parts designed for machining or fabrication often fight the casting process because the shape was not created with casting intent. Redstone reviews every part for wall-thickness uniformity, adds draft-angle guidance, and runs mold-flow analysis to catch high-porosity zones before tooling is cut.

The three main decision variables are material, part complexity, and volume. Aluminum plus complex shapes at meaningful volume points to die casting. Iron or steel plus intricate detail points to investment casting. Iron or steel plus simpler shapes or low volume points to sand casting, where tooling cost is low. In practice, facility capability, existing tooling, and lead-time constraints matter as much as any process-material fit chart. Redstone helps you select the right process for your specific part, not a lookup table.

Porosity in die cast parts is driven by wall-thickness inconsistency, gating design, and alloy or process mismatch. Trapped air in the die cavity creates internal voids that can affect mechanical properties and seal integrity. Prevention starts at DFM: wall-thickness review, process capability validation, optimized gating, and vacuum-assisted casting. Where leak integrity matters, X-ray inspection or leak testing is built into the control plan.

Redstone guarantees every part and will repair, replace, or refund. If a shipment fails inspection, the response is structured: 100% sort of the affected lot, containment of nonconforming inventory, root cause analysis before any corrective action, and a permanent fix to prevent recurrence. Options include Redstone-funded rework, air-freighted replacements, or credit for the affected pieces.