CustomPartNet
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October 21, 2026
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Updated October 21, 2026
A good place to start is narrowing the supplier list to those that match your needs, such as aluminum cold chamber capability, machine tonnage, or automotive quality certifications. Location matters because it affects freight and lead time, and Michigan’s automotive supply base puts many suppliers close to vehicle programs. For long-term, high-volume programs, picking the right die caster can be as important as the part design. Ask for sample castings similar to your part, since they show surface quality and detail in a way a quote sheet cannot. Browse our supplier network to compare qualified Michigan suppliers, examine sample parts, and request quotes.
Die casting produces geometrically complex metal parts using reusable molds called dies. A non-ferrous metal, typically aluminum or zinc, is melted in a furnace and injected into the die casting machine’s dies, where it rapidly cools and solidifies into the final casting. Castings can range from a couple of ounces to 100 pounds.
Aluminum has a high melting temperature, so it is cast on a cold chamber machine. The molten metal is held in a furnace pot that is kept separate from the machine, and metal is ladled into the shot chamber for each casting. A hydraulically powered plunger then drives the metal into the die at typical injection pressures between 2,000 and 20,000 psi.
The injection time is very short, typically less than 0.1 seconds, to keep any part of the metal from solidifying early. The plunger holds pressure while the casting solidifies, then retracts. The die opens, the ejection system pushes the casting out, and the die closes for the next cycle.
Finally, the casting is trimmed to remove excess material from the channels, along with any flash. Overall cycle times run between 2 seconds and 1 minute.
Aluminum is a natural match for electric vehicles, where weight and heat both matter:
Low density, which helps reduce vehicle weight and extend range
High thermal conductivity for heat dissipation from motors and electronics
High electrical conductivity
Good corrosion resistance
High dimensional stability
Relatively easy to cast
Thin walls and complex shapes can be cast as one part
The dies are the custom tooling. They have two halves, the cover die on the stationary platen and the ejector die on the movable platen, which open and close along the parting line. Inside, the cavity and core inserts form the part cavity. The die also includes the injection sleeve, runners, gates, overflow wells, vents, and cooling channels that carry water or oil to remove heat.
Dies are typically high grade tool steel, which is commonly used for 100,000 to 150,000 cycles. Aluminum’s higher casting temperature is harder on die life than zinc, so die life is a consideration for high-volume EV programs.
Tooling cost is influenced by:
Casting envelope size and die set size
Projected area and depth of the cavity
Number of features
Side-cores and side-action directions
Tolerance and surface finish requirements
Expected production quantity
Design rules that help aluminum castings:
Keep wall thickness uniform and as thin as practical
Round inside corners to at least the wall thickness
Apply 1° of draft on walls and 2° on inside cores
Minimize external undercuts, which add side-cores
Avoid internal undercuts that need lifters
Aluminum die casting is used throughout the electric vehicle industry to produce:
Battery housings and enclosures
Electric motor housings
Inverter and power electronics cases
Cooling plates and heat sinks
Gearbox and transmission housings
Charging port components
Structural brackets and mounts
Onboard charger housings
Cover plates and end caps
Sensor and control unit housings
Michigan suppliers support prototype and production programs for automotive OEMs, Tier 1 suppliers, and startups across North America.
Aluminum is lightweight, conducts heat well, and resists corrosion, which suits parts like motor housings and battery enclosures. It is also relatively easy to cast into complex, thin-walled shapes.
Cost depends on tooling, material, and production. Tooling is driven by die size and the machining of the cavities. Material cost depends on part weight and aluminum price. Production cost depends on machine size and cycle time. Cold chamber machines are typically more expensive to run than hot chamber machines, and cost per part drops at higher volumes.
It is a die casting machine used for alloys with high melting temperatures, such as aluminum. The molten metal is ladled into a shot chamber for each shot instead of being pumped, which protects the machine from the heat of the metal.
Often for critical features such as bearing bores, sealing faces, and mounting surfaces. Castings are produced near net shape, so machining is usually limited to those features.
Common issues include flash, unfilled sections, bubbles, hot tearing, and ejector marks. Many come from non-uniform cooling, so uniform walls and good die temperature control are important.
Thinner walls reduce part volume and shorten cooling time, which typically lowers material and production cost. However, very thin walls need a larger channel system so the metal fills quickly, so work with your supplier to find a good balance.
Yes. Many Michigan suppliers offer design for manufacturing feedback, tooling, casting, trimming, machining, finishing, and assembly. Die casting is most economical at medium to high volumes, since tooling cost is spread over more parts.
Get competitive quotes from Michigan die casting suppliers experienced with aluminum EV parts. Upload a CAD file, drawing, or product concept and receive quotes from qualified suppliers matched to your project.
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