High Pressure Die Casting (HPDC) is a manufacturing process in which molten metal is injected into a mold under high pressure and high speed conditions, and castings are obtained after cold confirmation. It is widely used for creating precise, high-quality metal components with excellent surface finishes and complex geometries. This process is commonly applied in the production of parts made from lightweight metals like aluminum, magnesium, and zinc.
High Precision: Produces components with tight dimensional tolerances.
Efficiency: Low per-part cost in high-volume production.
Material Savings: Minimal waste compared to other casting methods.
Strength and Light Weight: Especially for aluminum and magnesium parts.
Innovaw's primary mission is to meet customer expectations in quality, delivery, and performance. From design to die casting and machining, we possess end-to-end capabilities to deliver one-stop high-pressure die casting solutions for our customers.
During the design phase, our engineers will collaborate with your design team to optimize product design details through DFM analysis, establishing mutually agreed-upon product standards and the most suitable manufacturing processes.
• Leveraging our superior die-casting technology and experience, we implement DFM to achieve cost control, prevent quality defects, enable rapid mass production, and ensure sustainable manufacturing.
We perform mold design using CAD and conduct flow analysis simulations with CAE. Designs are meticulously reviewed from all angles to predict and optimize various process parameters. Following design reviews, we finalize the mold and high-pressure die casting process designs.
• We evaluate all mold characteristics and options to minimize potential risks during the casting process.
Production of high-pressure die casting molds commences based on finalized designs, encompassing moving and fixed dies, cores, gating systems, venting systems, cooling systems, ejection systems, and slides.
• Mold fabrication utilizes advanced CNC machining centers alongside EDM (electrical discharge machining) and wire cutting equipment.
• Mold modifications are implemented promptly based on real-time casting feedback.
Our high pressure die casting production line include 20 hot-chamber and cold-chamber die casting machines, ranging from 280 to 3,000 tons, with brand such us Swiss BUHLER, Japanese Toshiba and Chinese L.K. etc.
• Products size range from 10x20mm to 800x1100mm, weight ranging from 10g to 20Kg, daily production capacity 16-20 tons.
• Products can be as small as 1mm thick, with tolerances to ISO8062CT Class 5 after die casting
Automatic scooping, lubrication, spraying, and robotic extraction ensure consistently high product quality and efficiency.
• Innovaw's high-pressure die casting production lines operate fully automated in practice.
• All parameters—temperature, pressure, speed, cooling, etc.—are programmatically controlled.
• Integrated with ERP systems and MES management ensures on-time delivery for every customer order.
Integrating advanced sensor technology and adaptive control systems, this intelligent workstation combines grinding, deburring, and polishing into one integrated solution. It ensures uniform surface quality and achieves exceptional dimensional tolerances.
• Delivers over 300% greater efficiency compared to manual operations.
We have more than 30 CNC machining centers of brands such as DMG Mori and Japan's MAZAK, BROTHER, and the U.S HASS.
• Enabling one-stop service from high-pressure die casting to machining.
• A full range of CNC machining centers covering multiple processes including CNC milling, turning, drilling, tapping, and grinding. Processing precision reaches up to 0.008µm.
Our foundry possesses casting capabilities for materials including aluminum, magnesium, and zinc, with all materials meeting major international standards such as ASTM, JIS, DIN, ENAC, ISO, and GB. Commonly used materials are as follows:
ASTM-A413, A360, A380, A383
JIS-ADC1, ADC3, ADC10, ADC12
DIN-AlSi12, AlSi10Mg, AlSi8Cu3
AlSi11Cu3, AlS110MnMg, AlSi10Mn, AlSi9Cu3, AlSi11Cu2
ENAC-44100, 43400, 46000, 46400, 43500, 46500
KAlloy
ZnAl4, ZnAl4Cu0.4, ZnAl4Cu1
ZnAl4Cu3, #2, #3, #5, #7
AZ91D, AM60B
High-pressure die casting is a manufacturing process for producing metal parts such as aluminum, magnesium, and zinc, characterized by high precision, excellent surface finish, and strict tolerances. Upon receiving customer drawings, Innovaw engineers conduct DFM analysis to design and manufacture corresponding high-pressure die casting molds. The process then proceeds to die casting production, with the specific workflow as follows:
High-pressure die casting process is mainly suitable for low melting point metals (such as aluminum, zinc, magnesium), high melting point metals (such as steel) due to the rapid wear and tear of the mold is rarely used. Mainstream application materials are mainly several kinds:
1. aluminum alloy, such as ADC12, A380, with lightweight, good thermal and electrical conductivity, corrosion resistance and complex thin-walled parts molding ability, widely used.
2. zinc alloy, such as ZA-8, ZAMAK, good mobility and low cost, suitable for small precision parts
3. magnesium alloy, such as AZ91D, suitable for aerospace, medical equipment and other lightweight and other lightweight parts.
If you look only at the production process, high pressure die casting usually delivers faster than other casting processes. The main reason is:
1. high pressure die casting using metal mold, alloy under high pressure to fill the mold cavity quickly, cooling is also very fast, a part of the molding cycle may be only a few seconds to dozens of seconds, far faster than sand casting and other processes.
2. need less post-processing
3. high degree of automation, easy to improve production speed.
4. mold life is long, repeat times.
But from the whole process link to consider, high pressure die casting mold development cycle is long, high cost, general product structure is more complex, may need more trial mold time.
Overall, in medium and large volume production, high pressure die casting is usually one of the fastest casting process for delivery.
| Feature | Low-Pressure Die Casting | High-Pressure Die Casting |
|---|---|---|
| Pressure | Low (0.1-1 MPa) | High (10-200 MPa) |
| Casting Speed | Slower | Faster |
| Surface Finish | Good | Excellent |
| Mechanical Properties | Higher density, stronger | Less dense, good for thin walls |
| Complexity | Moderate | High |
| Typical Applications | Larger, load-bearing parts | Lightweight, precise parts |
Low-pressure die casting (0.1-1 MPa) produces stronger, higher-density load-bearing components at slower speeds, while high-pressure die casting (10-200 MPa) enables faster production of precision thin-walled parts with superior surface finish.
| Parameter | Cold Chamber Die Casting | Hot Chamber Die Casting |
|---|---|---|
| Heating Location | External furnace | Integrated furnace with die |
| Injection Speed | Relatively slow | Fast |
| Automation Level | Medium | High |
| Material Compatibility | High-melting-point metals (Al, Cu) | Low-melting-point metals (Zn, Mg) |
| Die Corrosion | Less severe | More severe (injection parts contact molten metal) |
| Typical Applications | Large structural components | Small precision parts |
Cold chamber die casting and hot chamber die casting are two common high-pressure die casting processes, which are mainly used to manufacture metal parts with complex shapes, high precision and smooth surfaces. Their main difference lies in the metal heating method and the structure of the die-casting machine is different, so the applicable materials are also different.
1. Cold chamber die casting (Cold Chamber Die Casting)
Cold chamber die casting process is mainly characterized by molten metal is heated in the furnace outside the die casting machine. The molten metal is poured into the pressure chamber (called the cold chamber because there is no additional heating) either manually or automatically, and then a piston injects the metal into the mold under high pressure. The mold remains cool throughout the process.
The main advantage of cold chamber die casting is that it is suitable for metals with higher melting points, while the mold and the pressure chamber have a longer life and are suitable for mass production of large, structurally complex parts.
Cold chamber die casting material: aluminum alloy (Al), magnesium alloy (Mg), copper alloy (Cu)
2. Hot chamber die casting (Hot Chamber Die Casting)
Hot chamber die casting process is mainly characterized by the furnace and die casting machine as a whole, the ejection mechanism immersed in molten metal, piston will be molten metal directly from the furnace into the mold. Hot chamber die casting process automation degree is high, suitable for the production of fast beat small parts.
The advantages of hot chamber die casting are high degree of automation, high production efficiency, fast injection speed, suitable for thin-walled parts. Simple operation, low production cost.
Hot chamber die casting applicable materials: zinc alloy (Zn), tin alloy (Sn), magnesium alloy
As a parts buyer, how to efficiently and cost-effectively source high-quality products has become a core concern for companies. High pressure die casting (HPDC) as an advanced metal molding process, by virtue of its unique advantages, has become the ideal choice for the manufacture of many complex structure products.
1. What kind of products suitable for high pressure die casting?
If you need to purchase to meet the following characteristics of aluminum, zinc and other metal parts products, then suitable for high-pressure die casting process production:
2. Important advantages of high pressure die casting
For the above product demand, high pressure die casting process shows irreplaceable advantages:
Whether it is the pursuit of lightweight new energy automobile parts, need precision structure of 3C electronic products, or emphasize the appearance and durability of industrial equipment parts, high-pressure die-casting process can be through the high efficiency, high precision, low-cost characteristics, to help enterprises realize the rapid transformation from design to mass production.
