Pressure die casting
Also called: aluminium die casting, HPDC, zinc die casting, die casting job work, Zamak casting
Pressure die casting (HPDC) injects molten aluminium or zinc into a steel die at high pressure, making accurate, thin-walled parts quickly. The die is costly, so it suits large quantities: housings, brackets, covers and fittings.
Quick facts
- Metals
- Aluminium (e.g. ADC12, LM24, A380) and zinc (Zamak 3, 5)
- Dies
- Hot-work tool steel such as H13
- Wall thickness
- Thin walls possible, often 1.5–3 mm
- Tolerance and finish
- Closer and smoother than sand casting
- Best quantities
- Thousands upward, to pay for the die
- Finishing
- Trimming, machining, shot blasting, powder coating or plating
Points to know
- Some internal porosity is normal; mark faces that must be leak-tight or machined
- Design with draft angles and even wall thickness
- Ribs add strength without thick sections
- Machined faces and threads are usually done after casting
What to send
- 3D model and drawing, marking machined faces
- Alloy and any test requirements (leak test, X-ray)
- Yearly quantity
- Surface finish needed
- Who owns the die
Need pressure die casting done?
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Related job work
Machines
Questions
- When is pressure die casting worth it?
- When you need thousands of aluminium or zinc parts: the steel die is expensive, but each part then costs little and needs little machining.
- Can die castings be welded?
- Generally not well, because of trapped gas and porosity. Design them to be bolted or assembled instead.
The figures on this page are typical values for guidance, written by Diemeco from standard engineering practice. They are not a specification: confirm grades and properties with the relevant standard or the supplier's mill test certificate, and tolerances with your workshop. Last checked 8 October 2026.