Custom Die Casting Services
Baosheng provides end-to-end custom die casting services, seamlessly transitioning from rapid prototyping to high-volume manufacturing. Supported materials include aluminum, zinc, magnesium, and copper alloys, with capabilities for thin walls and complex geometries.
- 100K+ Mass Production Machining
- Tolerance as tight as ±0.01 mm
- Certified Materials to Choose From.
- OEM & ODM Supported
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What is Die Casting & How does it Work?
Die casting is a high-precision metal forming process that rapidly injects molten metal (such as aluminum, zinc, or magnesium alloys) into precision steel molds under extremely high pressure and velocity. Rapid cooling produces metal parts with accurate dimensions and smooth surfaces.
It is particularly suited for mass-producing complex shapes, thin-walled components, and high-demand parts.
The workflow is as follows:
- The mold closes and locks at high speed.
- The molten metal is instantly filled into the cavity by a high-pressure injection system.
- Cooling channels within the mold rapidly solidify the metal.
- The mold opens and ejects the finished part. One cycle typically takes 10 seconds to 2 minutes.
Die Casting Services Solution
BaoSheng utilizes advanced die-casting equipment and technology to provide high-quality custom die-cast components for various industries. We specialize in both hot-chamber and cold-chamber die-casting processes, offering aluminum, zinc, or magnesium alloys based on specific requirements.
Hot Chamber Die Casting
Hot chamber die casting is suitable for alloys with low melting points (such as zinc alloys and certain magnesium alloys).
The furnace is integrated with the injection system, allowing molten metal to be rapidly injected into the mold through a gooseneck tube.
Advantages:
- Extremely high production efficiency
- Excellent surface quality
- Suitable for thin-walled, small precision parts
Applicable Materials: Primarily zinc alloys, also suitable for certain low-melting-point magnesium alloys.
Simple, high-speed, and ideal for mass production.
Cold Chamber Die Casting
Cold chamber die casting is suitable for alloys with high melting points (such as aluminum alloys and certain magnesium alloys).
Molten metal is ladled from an external furnace into the cold chamber, then rapidly injected into the mold under high pressure by a piston.
Advantages:
- Suitable for high-melting-point, high-strength alloys
- High part strength and excellent pressure resistance
- Capable of producing large, complex structural components
Applicable Materials: Primarily aluminum alloys, also suitable for copper alloys and high-strength magnesium alloys.
Ideal for medium to large parts, high-strength requirements, and high-volume production.
Sand Casting
Using sand to create a mold (sand mold), molten metal is poured into the sand mold. After cooling and solidifying, the sand mold is broken apart to remove the casting.
Key Features:
- Extremely low mold cost (sand molds are single-use)
- Suitable for large-sized, complex-shaped, and heavy components
- Longer production cycle with generally lower surface finish
- Most economical for single-piece, small-batch, or prototype production
Applicable Materials:
Nearly all castable metals: aluminum alloys, cast iron, cast steel, copper alloys, magnesium alloys, etc.
Gravity Die Casting
Gravity die casting involves pouring molten metal into a permanent metal mold (steel or iron) using gravity, then removing the casting after cooling and solidification.
Key Features:
- Molds can be reused thousands to tens of thousands of times
- Superior surface quality and dimensional accuracy compared to sand casting
- Lower cost and significantly reduced mold expenses compared to high-pressure die casting
- Dense internal structure with minimal porosity, superior mechanical properties compared to sand casting
Advantages:
- Excellent surface finish
- High dimensional accuracy (typically IT8 to IT10)
- Suitable for medium-volume production
- Part strength and airtightness superior to sand casting
Applicable Materials:
Primary aluminum alloys, magnesium alloys, copper alloys, zinc alloys (common in low-pressure gravity casting)
Vacuum Die Casting
Vacuum Die Casting = High-Pressure Die Casting + Vacuum Extraction
Cavity evacuated to near-vacuum prior to injection → Minimal porosity → Denser, stronger castings.
Core Advantages:
- Near-zero porosity
- Significantly enhanced strength/ductility
- Surface suitable for anodizing/electroplating
- Suitable for heat treatment (T6)
Primary Materials: Aluminum alloys, magnesium alloys
Low Pressure Die Casting
Using low-pressure gas (0.02–0.06 MPa), the molten metal is gently pushed from the bottom to fill the permanent metal mold.
Core Advantages:
- Virtually no porosity, dense structure
- Excellent mechanical properties
- Superior surface quality
- Suitable for heat treatment
Primary Materials: Aluminum alloys (especially A356 and similar grades)
Ready to turn complex designs into high-quality die cast parts?
Die Cast Metal Materials
Aluminum Die Casting
Lightweight and strong, aluminum is ideal for automotive and aerospace parts requiring durability and minimal weight.
Aluminum ADC12、ADC6、A360、A380
Magnesium Die Casting
The lightest structural metal, magnesium offers an excellent stiffness-to-weight ratio, ideal for weight-sensitive applications.
Magnesium AZ91D, AM60B
Copper Die Casting
Copper is excellent for parts such as heat sinks and electrical connectors because it conducts heat and electricity very effectively.
Copper ZQA19-2, ZQA19-4, ZQA19-7, ZQA19-10
Zinc Die Casting
Known for its toughness, zinc enables precise, high-tolerance casting for intricate designs and durable components.
Zinc Zamak 3, Zamak 5, Zamak 2, ZA8
Die Casting Surface Finishing
Standard (As-Cast)
Zinc and aluminum-zinc cast parts can be used in the as-cast condition with reasonable corrosion resistance, whereas aluminum castings generally require coating for corrosion protection. As-cast parts typically exhibit gate break-off marks and ejector pin marks, with a relatively coarse but consistent surface finish.
Bead Blasted
The part surface is left with a smooth, matte appearance.
Anodized (Type II Or Type III)
Aluminum cast parts are typically anodized to improve corrosion resistance. Type II provides basic protection, while Type III adds a thicker, wear-resistant layer. Anodized surfaces are not electrically conductive.
Powder Coating
All die cast parts can be powder coated. The process applies electrostatically charged powder and cures it by baking, forming a durable, wear- and corrosion-resistant coating available in a wide range of colors.
Wet Painting
All die cast parts can be wet painted in a wide variety of paint formulations and colors.
Plating
Die cast parts can be plated with electroless nickel, nickel, brass, tin, chrome, chromate, Teflon, silver and gold.
Chemical Film
Suppliers can apply a chromate conversion coating to improve aluminum corrosion resistance and enhance paint or primer adhesion. This type of chemical film remains electrically conductive.
Media Tumbled
Die cast materials are subjected to vibratory media tumbling to remove sharp edged and smooth surfaces.
Quality Assurance
At BaoSheng, quality guides every step. Our ISO 9001, ISO 14001, and IATF 16949 certifications ensure consistent, reliable manufacturing.
Advanced Inspection Equipment
BaoSheng uses precision testing tools to ensure part accuracy. Spectrometers check metal composition, coordinate measuring machines handle complex 3D shapes, 2.5D instruments verify detailed features, and height gauges measure basic dimensions.
Comprehensive Testing Procedures
All parts undergo material analysis, durability, corrosion, and functional tests to ensure they meet specifications, withstand demanding conditions, resist environmental damage, and perform reliably.
Proven Quality Standards
Most parts pass first article inspection on the first try. If any issue arises, we offer free remakes. Every part is thoroughly checked before leaving our facility.
Experience BaoSheng’s quality firsthand—request a quote today.
Why Choose BaoSheng Die Casting Services
Fast Lead Time
BaoSheng partners with top Chinese die casting manufacturers to ensure fast, reliable production. Our advanced facilities manage complex projects while providing transparent updates at every stage.
Cost-effective Solutions
Offers transparent, competitive pricing with no hidden fees. We optimize material use and select the most efficient casting process to help you plan your budget confidently.
Quality Assurance
ISO 9001:2015 certified, with rigorous quality checks at every stage—from pre-production to first article inspection and final delivery. We maintain tight tolerances as precise as ±0.01 mm.
Applications of Die Casting
Die casting serves a wide range of industries due to its precision, repeatability, and ability to produce strong, detailed parts at scale. At BaoSheng, we help businesses transform complex designs into production-ready components efficiently. Key applications include:
Automotive
Durable, dimensionally stable parts such as housings and brackets, suitable for high-heat, safety-critical environments.
Consumer Electronics
Internal frames, enclosures, and connectors that combine strength with compact, sleek design for high-use devices.
Lighting
Lightweight, intricate housings that deliver both functional performance and aesthetic appeal.
Medical Devices
Precision, clean-finished parts for tools and housings where consistency and hygiene are essential.
Advantages of Die Casting
High precision and repeatability
Supports complex, detailed geometries
Strong and dimensionally stable parts
Fast cycle times for mass production
Good surface finish with minimal machining
Efficient material usage
Disadvantages of Die Casting
High initial tooling cost
Not economical for low-volume production
Limited to specific alloys
Design changes after tooling are costly
Potential for porosity in thick sections
Die Casting Services FAQs
Can you post-machine die cast parts?
Post-machining is commonly used in die casting to achieve tighter tolerances, improved surface finish, and higher dimensional accuracy. CNC machining processes such as drilling and milling are applied to critical features that cannot be produced by die casting alone, while also correcting minor casting defects. By combining die casting with post-machining, manufacturers achieve cost-efficient production with precision suitable for demanding industrial applications.
What is an example of die casting?
Automotive transmission housings are a typical high-pressure aluminum die casting application. These complex parts require excellent dimensional stability, strong mechanical performance, and high heat resistance. Die casting allows integrated oil channels, mounting features, and precise bearing surfaces to be formed in a single process, reducing machining while maintaining tight tolerances.
Is die casting easy?
Die casting is a complex manufacturing process that requires specialized expertise, advanced equipment, and precise process control. Success depends on managing critical variables such as molten metal temperature, injection pressure, and cooling rates. Effective die casting also demands strong knowledge of metallurgy, fluid dynamics, and tooling design, supported by strict quality controls and experienced operators to ensure consistent, high-quality parts.
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