High Pressure Die Casting Service
Star Rapid offers a turn-key high pressure die casting solution for your product development needs. Not only do we make exceptional casting dies and parts, but we also offer CNC machining, plating, anodizing, powder coating – all the additional manufacturing services needed for a complete finished product.
What Is High Pressure Die Casting?
High pressure die casting involves the injection of molten metal, under enormous pressure, into the hollow cavity of a custom-made steel forming die. It’s the fastest and most cost-effective way to produce medium to high volumes of metal parts with excellent surface finish and dimensional accuracy.
Advantages Of High Pressure Die Casting
- Works with aluminum, zinc and magnesium
- Mold tools can make tens of thousands of parts economically
- Surface finish and accuracy are excellent
- Complex geometries can be achieved
- Especially suited for larger metal parts
Why Choose Star Rapid for High Pressure Die Casting?
Star Rapid is a recognized leader in providing sophisticated forming dies to make high-quality finished metal parts. More than just a service provider, we’re dedicated to being your true product development partner. Here are just a few reasons why thousands of businesses worldwide choose to work with Star Rapid.
✓ Services That Go the Extra Step
Many pressure die cast parts require additional machining services before they can be put into service. We provide threaded holes, machined faces, o-ring grooves, undercuts, keyways, and other complex features.
✓ Positive Material Identification
All raw materials used in our high pressure die casting service, for tooling as well as finished parts, are verified with positive material identification using advanced scientific measuring and test equipment.
✓ Industry Leadership
A multi-disciplinary team of international manufacturing professionals work with you to optimize your product designs to achieve maximum efficiency and product performance.
✓ Proven Results
Our pressure die casting services are used in agriculture, automotive, industrial and commercial applications around the world. Explore the See Our Past Projects section on this page to read some of our many success stories.
✓ Intelligent and Competitive Pricing
Our pressure die casting services are among the most affordable in the industry and are typically priced lower than most US, EU and AU manufacturers. To eliminate hassle, we never require a minimum order volume or minimum dollar value. Plus, we use state-of-the-art AI quotation algorithms to get you your quote quickly, in 24 hours or less for nearly all projects.
The Gate smart lock is an innovative and award-winning door security and communications solution. In this case study, learn how we worked closely with Gate Labs to offer essential design for manufacturing insights that improved the final product’s fit, finish and performance.
This aluminum die cast housing was made for ErvoCom AG to house vital telecommunications equipment for commuter trains. Learn how we worked with ErvoCom to create a die casting that met their high standards for fire safety and performance.
The High Pressure Die Casting Process
The success of your high pressure die casting project depends on the quality of the mold tools, and our tool making abilities are unmatched in Asia. After we receive your order, we will:
- Perform a complete Design for Manufacturing review of your CAD files.
- Verify tooling and product raw materials for compliance.
- Use our multi-axis imported CNC machine tools to fabricate the core and cavity.
- Apply careful heat treating to temper the molds.
- Exercise process control when casting your parts.
- Provide any necessary post-machining or processing.
- Professionally inspect and measure finished parts to meet and exceed your specifications.
High Pressure Die Casting Tolerances
We follow the standard NADCA tolerances for high pressure die cast parts. However, if your requirements are very precise, additional post-process machining can help you to achieve your tolerances.
High Pressure Die Casting Materials
Our mold tools are usually made from H13 tool steel with a Rockwell hardness of 42-48. Specialty steels are available upon request.
Die Cast Parts
We provide high pressure die casting in several different alloys of aluminum, zinc, and magnesium. Your choice of materials may depend on cost, weight and performance. Here are some tips:
- Aluminum is ideal for strong, lighweight yet complex geometries. It can also be highly polished. Our alloys include ADC12, A380, ADC10 and A413.
- Zinc is the least expensive but is good for plating. Available alloys are Zinc #3 and #5.
- Magnesium offers the best strength-to-weight ratio for higher performance applications. We offer magnesium alloy AZ91D.
Our pressure die casting engineers are ready to work with you to make sure you get great parts fast. When you submit your 3D design files, we will consult with you to ensure design for manufacturability in order to get parts that meet and exceed your expectations. Contact us for your free quote and design review today.
Pressure Die Casting: Further Reading
Porosity — the formation of small holes or voids within a part — can sometimes be a problem in pressure die casting. Though the risk of porosity cannot be eliminated altogether, it can be greatly mitigated with proper design, careful process control, and meticulous finishing. Read this blog to learn more about how we control and eliminate porosity. Read more…
Star Rapid Pressure Die Casting Service FAQ
What makes Star Rapid’s pressure die casting service unique?
Our specialists have decades of experience making the finest pressure die castings from aluminum, magnesium and zinc. These parts are routinely used in a variety of aerospace, automotive, industrial and commercial applications. We also pride ourselves on the breadth of our finishing services, which include CNC machining, plating, anodizing, painting, EDM surfacing and many more.
Can Star Rapid provide design services, industrial design support or product development support as an extension of its pressure die casting services?
Yes. An essential part of our pressure die casting process is our expanded service geared for design-for-manufacturing support. While we once reserved this service only for approved orders, we now provide it to all incoming RFQs. We also offer light assembly services to serve your needs.
What are Star Rapid’s quality standards for its pressure die casting services?
Our rigorous quality standards set our team apart from other pressure die casting services. As with all of our volume manufacturing services, the secret to getting great parts is consistency.
We verify the raw materials, control the environmental conditions during production and monitor all casting parameters. We provide Certificate of Compliance (CoC) documentation as well as final inspection and quality assurance data.
How do I get a quote for Star Rapid’s pressure die casting services?
We make it easy to get a fast quotation. Simply upload your CAD files and product details and we’ll send you a free quotation within 24 hrs. or less.
Request Your Free Pressure Die Casting Quote Today
Our improved algorithm decreases pressure die casting quotation times by up to 90%. Most quotes are delivered within 24 hrs. and usually much less, depending on project details.
Your customer support partner will contact you directly to ensure you’ve received and understand all aspects of your quotation and to answer any questions you may have.