Confidential Project Handling
Engineering Review
Global Delivery Support
Consistent Part Geometry
Repeatable dimensions help maintain alignment between housings, mounting points, and mating components across production batches.
Die Casting Services
Custom Die Casting for Repeatable Metal Parts
GD Prototyping’s die casting services combine tooling review, secondary machining, and finishing to support consistent dimensions and efficient production of custom metal parts.
- Confidential Project Handling
- Engineering Review
- Global Delivery Support
What Is Die Casting?
Die casting forms metal parts by injecting molten alloy under pressure into a reusable steel mold. The metal solidifies into the mold’s shape, creating features such as ribs, bosses, and thin walls.
Aluminum, zinc, and magnesium alloys are commonly used for die cast parts. Repeat production spreads tooling costs across more parts, while secondary machining can bring critical holes and mating surfaces to their specified tolerances.
Key Benefits of Die Casting
Efficient Repeat Production
Reusable die cast tooling and short casting cycles support efficient output for recurring production orders.
Integrated Cast Features
Combine ribs, bosses, and mounting features in one casting to reduce separate components and assembly steps.
Reduced Material Removal
Near-net-shape die cast parts can reduce bulk material removal compared with machining from solid stock.
Versatile Surface Finishing
1. Alloy-compatible coatings and cosmetic treatments help meet appearance and corrosion-protection requirements.
Included Die Casting Services
Aluminum Die Casting
Aluminum die casting for lightweight housings, brackets, and heat-dissipating metal components.
Zinc Die Casting
Zinc die casting for fine details, thin walls, and plated components.
Magnesium Die Casting
Magnesium die casting for lightweight enclosures and weight-sensitive structural components.
How It Works
How Our Die Casting
Service Works
Design & Alloy Review
Review CAD files, quantities, alloy requirements, wall thickness, draft angles, and critical dimensions to assess casting feasibility.
Die Design & Tooling
Plan the die casting mold, including gating, cooling, venting, and ejection, with allowances for shrinkage and secondary machining.
Die Trials & Sample Review
Run trial castings and review sample dimensions, appearance, and fit before approving the production setup.
Controlled Casting
Produce the agreed quantity using the approved die and process settings, with checks at defined production stages.
Machining & Surface Finishing
Trim gates and flash, machine specified features, and apply alloy-compatible surface treatments according to project requirements.
Inspection & Delivery
1. Check finished parts against drawings and agreed inspection criteria, then protect, package, and arrange shipment.
Die Casting Materials & Project Considerations
Metals
Illustrative material appearance; final grade and finish are project-specific.Lightweight, corrosion-resistant aluminum for CNC-machined prototypes, brackets, housings, and precision parts.
Aluminum 6061Aluminum 6063
Aluminum 6082
Aluminum 7075
Aluminum 5052
Aluminum 2024
Plastics
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Die Casting Finishing & Secondary Options
Powder Coating
Cured powder coatings for metal parts, with varied colors and textures.
Painting
Industrial painting for specified colors, gloss levels, and application-specific surface protection.
Electroplating
Electrically deposited metal coatings for protective, conductive, or decorative applications.
Sand Blasting
Abrasive blasting for matte textures and metal surface preparation before coating.
Polishing
Mechanical polishing for smoother surfaces and satin, bright, or mirror finishes.
Electrophoresis
Electrodeposited paint coatings for prepared conductive metal components and assemblies.
Alodine
Aluminum conversion coating for corrosion protection and improved paint adhesion.
Electroless Plating
Chemically deposited metal coatings with relatively uniform thickness on compatible, prepared surfaces.
Die Casting Applications
Advantages
Why Work With GD Prototyping?
Our die casting services connect tooling, machining, and finishing within one project scope, helping reduce separate sourcing while keeping assembly and inspection requirements aligned.
DFM Before Tooling
Early design review addresses casting risks before tooling investment, helping reduce avoidable mold changes and production rework.
Coordinated Manufacturing
Combine casting, secondary machining, and finishing in one project to reduce sourcing effort and process handoffs.
Alloy & Finish Compatibility
Balance casting performance, mechanical properties, and surface treatment compatibility around the part’s function and operating environment.
Inspection Documentation
Agree critical dimensions and inspection needs upfront, with dimensional reports and material certifications available on request.
Tooling for Repeat Orders
Maintain die cast tooling for recurring orders, with proposed design changes reviewed for practical mold modification options.
Global Delivery Support
1. Protect critical surfaces during packing and coordinate shipment around the agreed project delivery requirements.
FAQ
Die Casting FAQs
Which alloys are available for die casting?
Aluminum, zinc, and magnesium alloys, selected according to strength, weight, corrosion resistance, and finish requirements.
What affects die casting cost?
Mold complexity, alloy, order quantity, and required machining or finishing determine tooling and per-part costs.
What tolerances can die cast parts achieve?
Tolerances depend on alloy, geometry, and tooling. Critical dimensions are reviewed individually and may require secondary machining.
Which die casting surface finishes are available?
Options include blasting, polishing, painting, powder coating, and plating, subject to alloy compatibility and project requirements.
What should I provide for a custom die casting quote?
1. Send CAD files, drawings, alloy requirements, quantity, surface finish, critical dimensions, and your required delivery date.
After-Sales Support
Our commitment does not end at delivery. We provide comprehensive after-sales support to ensure your satisfaction and long-term success.
Engineering Follow-Up
Ongoing technical support to address questions and improve future designs.
Quality Issue Response
Rapid investigation and corrective action to resolve any quality concerns.
Inspection Reports
Detailed inspection reports and certificates available with every order.
Process Continuity
Documented processes and tooling management ensure consistency for repeat orders.
Packaging & Logistics Support
Secure packaging and logistics coordination across orders.
Quick Reorder Support
Easy reorder process and manufacturing communication.
Ready to discuss your
die casting project?
Send your files, drawings, material notes, quantity, finish requirements, and critical features for a project-specific review.
- Engineering Review
- Confidential File Handling
- Delivery Support