It is one of the most efficient and cost-effective methods of manufacturing metal parts and products of complex shapes and sizes in a variety of lightweight, high-strength materials. The production cycle is fairly simple, quick and easily repeatable. Hence, large quantities of the part or product can be manufactured in a matter of minutes and with a minimum requirement for post-production machining. What’s more, a variety of surface textures and finishes can be applied to the final product, such as anti-corrosion coatings and specialised, aesthetically pleasing finishes. This manufacturing method is also said to consume less energy and produce less material wastage than other metal shaping processes.

Die casting is not suitable for low-volume production. Most manufacturers will quote a minimum order quantity (MOQ) because they make their profits from producing goods in bulk. The MOQ might vary depending on the raw material you request. Another factor to consider is tooling cost, which can run into the hundreds of thousands of dollars if you require a complex or large part to be cast. The time it takes to create your custom tool can also add to your lead time. Furthermore, if a tool requires modification after it has been made, this could reduce tool life and reliability down the line.

Tooling can be expensive compared to other types of casting. It is also unlikely that the manufacturer will offer samples and prototypes from the tool, unless you pay for the tool.

Usually, tools last several years. A die, for example, can be used to make up to 500,000 castings. However, tool life depends significantly on the complexity of the part. An intricate and large part may have a different tool life compared to one with a simpler geometry.

The geometric complexity of the tool also affects cost and production speed. A simple tool can cost just a few hundred dollars to make whereas a larger or more intricate tool is more expensive to create. Similarly, a tool with greater geometric complexity will require a longer cooling time and, hence, a longer production cycle. This is why it is important to pay attention to the design of your product.

China is the market leader in metal die casting, accounting for close to 40% of the global market share. Chinese manufacturers offer some of the lowest per-unit prices in the world, thanks to the country’s low manufacturing costs, cheap labor, world-class infrastructure and superior supply chains. And, with the right checks in place, you can make sure that your Made-in-China products are of the highest quality. Though you can find factories just about anywhere in China, Hebei and Zhejiang provinces are the major hubs.