Aluminum Die Casting High Pressure Manufacturing Process

It is a manufacturing process that involves injecting molten Aluminum under high pressure into a die cavity. The die cavity consists of two separate dies that are clamped together to form a complete shape.

It is a sophisticated manufacturing process with some fundamental steps.


  • Firstly, die tooling for the desired parts are carried out by CNC Machining
  • The dies are usually divided into two segments that are clamped together to form a cavity
  • Aluminum alloy is melt under high temperatures in a separate container
  • Then poured into a chamber linked to the die cavity and forced inside with high pressure
  • The molten Aluminum spreads throughout the cavity and takes shape
  • After solidification and cooling the casting is removed


Aluminum Die Casting is referred to as a cold-chamber die casting process. This is because Aluminum has a high melting point that makes it difficult to melt directly on the die casting machine. Instead, it is melted inside a separate chamber and carried into the die casting machine.





It is one of the fastest and cost-effective methods for mass production of metal parts. Die Casting companies put their trust in Aluminum Die Casting due to its versatile scope of application and advantages.


Aluminum Die Casting can yield parts that are multiple times lighter than those produced using Iron or Zinc Alloys. The weight of parts is a big concern in the transportation sector. Because heavier vehicles will need a more powerful engine with more fuel consumption for operating. That’s why manufacturers prefer casting Aluminum for obtaining lighter parts.


Aluminum is one of the cheapest metals that is available all around the world. That alone is a major fact that most Die Casting Companies are offering Aluminum Die Casting services. Every company focuses on producing the best quality products with minimum production cost.

Excellent Strength-to-Weight Ratio

Aluminum Die Casting ensures an excellent Strength-to-Weight ratio. That allows thinner walls in the parts. Aluminum Die Casting of the same dimension is much stronger than most other metal alloys. So, the weight of products can be significantly reduced without hampering strength properties.

Higher rate of Production

Aluminum Die Casting is basically a mass production technique. You only need to do the die tooling once and use it for thousands of injections. So, the production cost per part is greatly reduced for larger quantities of parts produced.

Corrosion Resistance

Aluminum Die-Cast parts have greater corrosion resistance compared to others. Aluminum parts can be used without additional surface treatment or painting as it is not prone to oxidation. So, it can be used in harsh environments without any worries.

Excellent Conductivity

Aluminum Die Casting has gained popularity in the electronic industry as well. Aluminum alloy has a high electrical conductivity that makes it an ideal choice in many consumer electronic products. It also has a high thermal conductivity. It can retain strength at extreme temperatures.


The die manufactured parts, and excess material, everything is completely recyclable. So a minimum amount of waste is produced during Aluminum Die Casting. So, it is also a sustainable approach to manufacturing.


OLYMPUS DIGITAL CAMERA-Aluminum die casting


Die Casting technology was first applied in the printing industry in 1838. Back then it was used for producing movable type for printing. With technological advancement die casting eventually became an integrated part of the metalworking industry.

Now, Aluminum Die Casting has become more or less an industry standard for producing high-quality metal parts. The manufacturing industry prefers castings of Aluminum alloy more than Iron, Zinc, Magnesium, etc.



There has been a significant rise in popularity of Aluminum Die Casting in the following industries,

  • Automotive
  • Aerospace
  • Electronic
  • Construction
  • Telecommunication etc.

Most of the companies prefer Aluminum Die Casting mainly because you can get lighter parts. This is critically important in the transportation sector, namely the Automotive and Aerospace Industry. In these industries the lighter the parts the better.


Global Aluminum Die Casting market shareGrand View Research published a report on the global Aluminum Die Casting market, it stated the market size was valued at USD 24.91 billion in 2018. The report highlighted the increasing practice of Aluminum Die Casting in the transportation and construction sector.

The transportation sector alone was accounted for 61.5% of the market share in 2018. As the demand for fuel-efficient vehicles increases within the end-users, companies are shifting their focus on Aluminum Die Casting.


Die casting is a versatile process that allows a wide variety of metal alloys such as Aluminum, Zinc, Magnesium, Copper, Brass, Lead, etc. But among them, Aluminum, Zinc, and Magnesium are used more often.


Aluminum Die Casting on the other hand is more popular than the rest. Aluminum is readily available in nature. That’s why the production cost of Aluminum Die Casting is much cheaper than other alternatives. Aluminum Die Casting is known for its lightweight and durability. But when it comes to weight Magnesium Die Casting is the winner here. You can get the lightest parts with thin walls and tight tolerances with Magnesium Die Casting. However, Magnesium Die Casting is more expensive and yields parts with less strength compared to Aluminum Die Casting. If strength is not your primary concern and you need lighter parts regardless of the cost you may choose Magnesium Die Casting.


On the other hand, Zinc alloys have properties almost similar to that of Aluminum Alloys. And the cost is of them is quite similar as well. Zinc has a low melting point than Aluminum. So, it is manufactured by a hot chamber die casting process which is faster. Zinc Alloy has good strength properties. But a huge drawback is that it is much heavier compared to Aluminum alloys. So, those who need lighter parts will choose Aluminum over Zinc Die Casting. The Application of Zinc is mostly limited to die casting of smaller parts.