Die Casting Services — High-Pressure Aluminum & Zinc Die Castings

What is Die Casting?

Die casting is a high-pressure metal forming process in which molten metal is injected into a reusable steel mold (die) to produce complex, high-precision components at high volumes. Typical injection pressures range from 1,000 to 15,000 psi, and part tolerances for as-cast components commonly reach ±0.1 mm. For parts requiring higher precision, we provide integrated secondary machining such as turning, milling and finishing to meet tolerances down to ±0.005 mm.

Why Choose Die Casting?

Die casting offers excellent value for applications that require:

• High production efficiency and repeatability for medium to large volumes.

• Complex geometries and thin walls with consistent dimensional accuracy.

• Superior surface finish and easy integration of functional features (bosses, ribs, threaded inserts) directly in the mold.

• Cost advantages by minimizing secondary assembly and machining for well-designed parts.

Materials We Work With

We manufacture die castings using industry-standard alloys chosen for application requirements:

Aluminum alloys — ADC12, A380, A360, A356-T6, ZL102: lightweight, corrosion resistant, excellent thermal properties; ideal for automotive housings, lighting trims, heat sinks and structural components.
Zinc alloys — Zamak 3, Zamak 5, Zamak 7: high ductility and excellent surface finish, great for precision hardware, decorative fittings and components requiring plating or chrome finishes.
(We also support low-pressure and cold-chamber processes when application demands.)

Our Die Casting Capabilities

• Machine range: Die casting presses from 250 ton to 1,000 ton — able to produce small precision pieces and larger structural castings.

• Tooling & DFM: Mold preheat, venting, gating optimization, and DFM recommendations — we design for manufacturability to reduce cost and defects.

• Part size & weight: Wide single-piece size & weight range; custom quoting available per drawing.

• Secondary machining: In-house CNC turning, milling and drilling for finished tolerances and fitted features.

• Surface treatments: Nickel plating, chrome plating, powder coating (many colors), black powder coat, sand-blast, shot-blast, vibration polishing, chromate/clear iridite finishes and other protective/ decorative finishes.

• Assembly & finishing: Threaded inserts, O-ring installation, grounding screws, pre-assembly and delivery as sub-assemblies.

Equipment & Technology

We combine robust die casting presses with high-precision CNC centers and inspection tools:

• Cold-chamber/high-pressure die casting machines (250–1000 ton).

• Multi-axis CNC machining centers (capable of ±0.005 mm in critical operations).

• Surface treatment lines (plating, powder coating, shot blasting).

• Metrology: Coordinate Measuring Machines (CMM), gauges and full inspection fixtures.
  These assets let us take a part from prototype to production with tight control over quality and lead time.

Quality Control & Certifications

Quality is enforced throughout the process:

• Incoming material verification and certificate traceability.

• First article inspection, in-process checks, and final CMM inspection.

• Surface treatment quality checks and adhesion tests.

• Process documentation and production traceability.
  (We can support PPAP/APQP documentation and customer-specific quality requirements upon request.)

Industries We Serve

• Automotive & New Energy Vehicles — housings, brackets, transmission covers, motor parts.

• Lighting & Electronics — trims, LED bases, heat sinks.

• Industrial Machinery & Pumps — gearbox housings, pump bodies, valve plates.

• Medical & Gas Systems — medical gas outlet faceplates and fittings (with specialty coatings).

• Consumer & Decorative Hardware — chrome-plated handles, hinges, adapters and aesthetic components.

Typical Products & Case Examples

Examples of die-cast parts we produce:

• ADC12 / A380 automotive brackets, piston housings and structural components.

• Zamak-3 decorative faceplates, hinges and chrome-plated fittings.

• Powder-coated motor housings, sand-blasted valve plates and CNC-finished pontons.

• Assembled enclosures with O-rings and ground screws for lighting and electrical applications.

Design & Cost Advantages of Custom Die Casting

Custom die castings let you:

• Integrate multiple functions into one part (reduce assembly steps).

• Optimize wall thickness and ribbing for weight reduction and stiffness.

• Choose finishes that meet both functional and brand requirements.

• Lower long-term unit costs by minimizing secondary operations.

Industry Trends & Future-Readiness

We track and adopt industry trends:

• Integrated die casting — redesigning multi-part assemblies into single cast pieces using ultra-large machines.

• Lightweight alloys and applications in new energy vehicles and aerospace.

• Smart manufacturing — automation, production data monitoring and digital process control to improve yield and

  consistency.

Why NBI?

• Multi-process integration: die casting + precision CNC + surface treatment + assembly — one supplier for complete part delivery.

• Proven experience: 15+ years manufacturing complex die-cast parts with repeatable quality.

• End-to-end support: DFM, prototyping, small run to mass production, and after-sales service.

• Complete finishing: plating, powder coating, blasting and precision machining in-house to control cost and lead time.

Ready to get started?

Send us your drawing (STEP, DWG or PDF) or request a DFM review. We’ll provide a fast quote, manufacturability feedback and production plan tailored to your schedule.

 Start Your Project