High-Pressure Die Casting Services

High-pressure die casting injects molten metal into a hardened steel die under high pressure, then holds that pressure until the part solidifies. It fills the die quickly, supports thin walls and intricate features, and is built for high-volume non-ferrous production.

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.

We die cast aluminum and zinc alloys. Aluminum is lightweight, conductive, and corrosion resistant; zinc adds impact strength and ductility. Our engineering team confirms the best alloy for your part.

It 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.

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.

High-pressure 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.

We die cast aluminum and zinc alloys, the most common casting alloys for this process. Aluminum die casting suits lightweight, corrosion-resistant housings and enclosures, while zinc alloys add impact strength, ductility, and fine detail. Our engineering team confirms the right alloy for your part at the feasibility review.

Because the die casting process fills a hardened steel die cavity under pressure, parts come out near net shape with smooth surfaces and intricate features. From there we add machined finishing, bead blasting, powder coating, anodizing, and electroplating to match functional and cosmetic requirements.

High-pressure die casting holds tighter tolerances, produces a smoother surface finish, and runs at faster cycle rates than sand casting or investment casting. Its tooling cost is higher, so it is most cost-effective on sustained production runs. For lower quantities, sand casting or investment casting may be the better fit, and our engineering team recommends the right process at the feasibility review.

High-pressure die casting carries higher upfront tooling costs than sand or investment casting, so it is most cost-effective on recurring production volume. The process is limited to non-ferrous metals such as aluminum and zinc. Porosity from gas entrapment is an inherent risk, though it is managed through gating design, vacuum-assisted casting, and process validation. For lower quantities or ferrous metals, investment casting or sand casting may be a better fit.

Gas entrapment during the high-pressure casting cycle creates micro-porosity within the casting. Welding heat expands those trapped gas pockets, causing cracking and weak joints. For applications requiring welded joints, lower-porosity casting methods produce material that welds more reliably, and our engineering team can advise on the right process at the feasibility review.

Inconsistent wall thickness. Non-uniform walls cause uneven fill and cooling, leading to porosity, sink marks, warpage, and crack propagation. Redstone reviews every part for wall-thickness uniformity during DFM and provides draft-angle guidance to catch these issues before the die is cut.