CustomPartNet
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July 9, 2026
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Updated July 11, 2026
Start by narrowing your supplier list to those that match your specific requirements, such as material capability or required certifications. Factors like location can also have an impact on your shipping fee and lead time. Selecting the right supplier can be as important as the design of the part itself, especially for larger volumes or long-term collaborations.
It can also be helpful to compare sample parts with your project to determine if the supplier is the right fit. Not only are they physical proof of the supplier's capabilities, they are also a great visual indicator of what to expect, which can often be more helpful than numbers. Browse our supplier network on the right to compare qualified suppliers, examine sample parts, and request quotes.
Die casting is one of the most efficient manufacturing processes for the mass production of metal parts with tight tolerances and smooth surface finishes. It is particularly well-suited for high-volume production because a single die can produce large quantities of nearly identical parts with excellent repeatability.
The process begins with a molten metal such as aluminum, which is prepared in a furnace and held at a precise temperature until it is ready for injection. In high-pressure die casting, the molten metal is forced into a hardened steel mold, known as a die (and hence the process name), under significant pressure and at high velocity.
The die is held tightly closed by a clamping unit, allowing the aluminum to completely fill the cavity before it begins to solidify. The molten metal is continuously held at pressure so that any cavities from the metal shrinking as it cools can be filled immediately. Because metals have a high thermal conductivity and cool quickly, the entire fill and solidification stage typically happens in a matter of seconds.
Once the part has solidified, the die opens and the casting is ejected, often with the help of ejector pins. For larger or heavier parts, a human may need to aid in the part removal or for a custom part catcher to be installed in order to avoid damaging the part during ejection.
Any excess material, such as flash or sprues (channel that the metal is injected from) left behind from the shot, is trimmed away in a secondary trimming operation. The die then closes and the cycle repeats.
Die casting is capable of producing parts with excellent dimensional accuracy, thin walls, complex geometries, and surface finishes that often require little to no additional machining.
Die casting is only suitable for metals with a relatively low melting point because the die, also made from metal, needs to maintain its integrity during the process. Aluminum is one of the most commonly specified metals for die casting because it offers:
Excellent strength-to-weight ratio
Good corrosion resistance
High thermal and electrical conductivity
Dimensional stability at elevated temperatures
Compatibility with machining, plating, and painting
Recyclability and favorable material cost
Suitability for thin-wall, complex geometries
The die used in aluminum die casting is a precision-machined tool, typically constructed from hardened tool steel to withstand the repeated thermal cycling and high injection pressures involved in the process.
Mold (die) costs vary depending on:
Part size and complexity
Number of cavities
Core and slide requirements
Surface finish and cosmetic requirements
Expected production volume and tool life
Here are some common features that aluminum die cast parts typically require or can accomplish:
Thin-wall sections for weight reduction
Tight dimensional tolerances
Fine surface finishes for cosmetic or sealing applications
Cast-in bosses, ribs, and mounting features
Multi-cavity or family tooling for production efficiency
Secondary machining for critical features such as bores or threads
Aluminum die casting is widely used throughout the automotive, industrial, and consumer products industries to manufacture:
Engine and transmission components
Housings and brackets
Heat sinks
Electrical enclosures
Structural automotive components
Pump and motor housings
Lighting fixtures
Hand tool components
HVAC components
Industrial equipment housings
Ohio suppliers support both prototype and production programs for OEMs, tier suppliers, and industrial manufacturers throughout North America.
Aluminum provides an excellent balance of strength, weight, corrosion resistance, and cost. It also machines and finishes well, making it a practical choice for structural and cosmetic components alike.
Tooling costs typically range from $10,000 to $150,000+ depending on part complexity, size, and expected production volume. Per-part costs vary based on part weight, cycle time, and annual quantities.
Aluminum die cast parts can be produced with as-cast, machined, shot-blasted, polished, or plated finishes. Anodization is a popular finishing method for aluminum parts, but other methods such as powder coating or painting can be suitable too depending on the application.
Typical tolerances range from ±0.005" to ±0.015" depending on part geometry, wall thickness, and tooling quality. Critical dimensions may require secondary machining to hold tighter tolerances. Remember to always verify achievable tolerances with your supplier ahead of time to ensure there are no surprises and to minimize test batches.
Yes. Common die casting alloys include A380, A383, and A413, each offering different trade-offs in strength, fluidity, and corrosion resistance depending on the application. It is important to research this beforehand and discuss it with your supplier, as different alloys will have varying casting properties.
Yes. Many Ohio suppliers offer design-for-manufacturing support, mold design and build, prototyping, pilot production, full-scale manufacturing, machining, and finishing services.
Die casting is most economical for medium-to-high production volumes because tooling costs are amortized over larger quantities. Production runs commonly range from thousands to hundreds of thousands of parts.
Get competitive quotes from Ohio die casting suppliers experienced with aluminum mold making and production. Upload a CAD file, drawing, or product concept and receive quotes from qualified suppliers matched to your project requirements.
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