Custom Die Casting Services

There is no “one-size-fits-all” price in die casting because costs depend on four key drivers: tooling (the mold), material volume, part complexity, and production quantity.
Production Volume: The higher your volume, the lower the per-part cost, as tooling expenses are amortized over more units.
Complexity: Features like undercuts, tight tolerances, or thin walls add to design and tooling complexity.

Tip: To get a precise quote, upload your CAD files today. Our engineers will perform a free DFM (Design for Manufacturing) analysis to help you identify cost-saving design optimizations before you spend a dime on tooling.

• High-Speed Production: Perfect for scaling from hundreds to thousands of parts.

• Superior Surface Finish: Get smooth, retail-ready parts straight from the mold.

• Tight Tolerances: Consistency guaranteed up to ±0.01mm.

• Complex Geometries: Achieve intricate designs in a single production step.

How does RapidDirect minimize porosity in die cast parts?

When designing parts for die casting, several key considerations must be addressed to ensure optimal performance and manufacturability:

• Wall Thickness: Maintain uniform wall thickness to promote even cooling and solidification, reducing risks of defects like warping or internal stresses. Thin walls are preferred for faster cooling and material savings, but their feasibility depends on the metal used and part complexity.

• Draft Angles: Include draft angles in the design to facilitate the easy removal of the casting from the die. Typically, a minimum draft angle of 1 to 2 degrees is necessary, depending on the depth of the part.

• Fillet and Radii: Incorporate fillets and radii to eliminate sharp corners and edges, which can cause stress concentrations and crack initiation points. This adjustment also enhances the flow of molten metal within the die.

• Gating System: Design an efficient gating system to ensure proper flow of the molten metal into the die, minimizing turbulence and air entrapment. The placement of gates influences material distribution and part quality.

• Venting: Proper venting must be planned to allow air and gases to escape from the mold cavity during metal injection. This helps prevent porosity and incomplete filling.

• Simplifying Geometry: Simplify the geometry as much as possible to avoid undercuts and complex features that require intricate die mechanisms, which can increase tooling costs and complicate the casting process.

Yes, post-machining of die cast parts is not only possible but often necessary to achieve the desired precision and surface finishes that die casting alone might not provide. Post-machining allows for the attainment of tighter tolerances and smoother surfaces, which are crucial for high-performance and aesthetic requirements. Common post-machining processes include drilling, milling, and CNC machining, which refine the features of the die cast part to exact specifications.

Additionally, post-machining can correct any minor defects that occur during the casting process, such as porosity or surface imperfections. It also enables the addition of complex features and fine details that cannot be achieved through casting alone. By integrating die casting with post-machining, manufacturers can leverage the speed and cost-efficiency of die casting for the rough shape, while achieving the precision of CNC machining for critical dimensions and finishes.

The die casting process is a high-pressure manufacturing method where molten non-ferrous metal is injected into a precision-engineered steel mold (die). At RapidDirect, we follow a rigorous 5-step process to ensure every part meets your exact specifications:

1. Preparation & Clamping: We start by lubricating the die cavities to ensure easy part ejection and temperature control. The two halves of the mold are then securely clamped under high pressure.

2. Injection: Molten metal (aluminum, zinc, or magnesium) is forced into the die at high speed and pressure (typically between 1,500 and 25,000 psi). This ensures the metal fills even the most intricate geometries.

3. Cooling & Solidification: The metal quickly solidifies inside the mold. Our advanced cooling systems ensure uniform temperature distribution to minimize internal stresses and warping.

4. Ejection: Once cooled, the die opens, and the “shot” (the part plus the excess material like gates and runners) is ejected via hydraulic pins.

5. Trimming & Finishing: The excess material is trimmed away. Depending on your needs, we then perform secondary CNC machining or surface finishing (such as powder coating or anodizing) to complete the part.