Aluminum Die Casting
with Mastars
Durable, precise, cost-effective—aluminum die casting for high-volume production of automotive, medical, and consumer parts.
Aluminum Die Casting Service
Aluminum die casting forces molten aluminum/alloy into steel molds for part production. It enables intricate, precise (straight/flat) components with a fine surface finish, favored for high strength-to-weight ratio, corrosion resistance, and heat dissipation.
Die Casting Parts We Manufactured
Mastars Die Casting Capabilities
| Details | ||||
| Tolerance | High-precision die casted parts need secondary machining to meet tolerance requirements, achieving accuracy up to ±0.01mm | |||
| Minimum Wall Thickness | Aluminum alloy recommended 1.5mm, zinc alloy can go down to 0.8mm | |||
| Wall Thickness Ratio | Keep within 1:3 ratio to avoid uneven filling | |||
| Hole Diameter | Due to high temperatures during aluminum die casting mold processing, round holes smaller than 3mm diameter require secondary drilling. Product threaded holes and external threads are formed through secondary machining. | |||
| Draft Angle | Minimum 0.5° to avoid demolding difficulties | |||
| Maximum Die Life (Number of Cycles) | Zinc: 1,000,000 Magnesium, Aluminum: 100,000 | |||
| MOQs | 1 pieces | |||
| Lead Time | 3-10 days. Specific timing varies based on mold type and product structure complexity | |||
Why Choose Mastars for Die Casting
High-precision metal parts with integrated post-processing and full-BOM support.
T1 Samples As Fast As 3 Days
Mastars' Factory and Advanced Equipments
Our Ideas Have Helped Clients Bring Hundreds Of Products To Market
High Pressure Die Casting
A high-precision manufacturing solution that injects molten metal into steel molds at extreme pressures (1,000–20,000 psi) to produce tight-tolerance metal components efficiently.
High-pressure injection produces dense, tight-tolerance castings ideal for high-performance automotive and industrial parts.
Fast cycles & automation enable cost-effective mass production of consistent, intricate metal parts.
Works with diverse non-ferrous alloys to meet varied industry application needs.
Low Pressure Die Casting
Molten metal is poured gently and driven into molds via 7–30 PSI low-pressure gas—ensuring smooth filling and high-quality, defect-free cast components.
Gentle low-pressure filling minimizes casting defects like porosity, delivering high-density, premium-quality components ideal for critical applications.
Precise mold filling enables the production of complex, thin-walled parts that meet the lightweight design requirements of aerospace and automotive industries.
High material utilization and low energy consumption cut production costs, making it cost-effective for both small-batch customization and large-scale manufacturing.
Hot and Cold Chamber Die Casting
Cold-chamber casting is ideal for high-melting-point alloys (e.g., aluminum), while hot-chamber casting delivers faster production of complex, intricate components using low-melting-point alloys.
Dual-chamber casting supports high/low-melting alloys, perfectly fitting automotive, aerospace and electronics industry needs.
Streamlined hot/cold-chamber processes enable fast, precise manufacturing of intricate components for all production scales.
Tight-tolerance casting minimizes defects like porosity; finished parts feature high consistency with little to no post-processing.
Semi-solid Die Casting
Semi-solid die casting utilizes metal in a paste-like state (between liquid and solid). Heated to this condition, the metal is slowly injected into molds with minimal turbulence, reducing porosity, boosting part strength and improving surface finish. Ideal for aluminum and magnesium alloys, it produces high-quality automotive and aerospace components requiring superior strength.
Low-defect high-density forming
Ideal for light alloy applications
Superior surface finish & strength
Advanced Modeling and Design Software
Simulation Tools: Mold flow analysis for optimized casting Design Software: Advanced CAD and CAM systems
Enables precise mold/part design to optimize manufacturability.
Shortens development cycles and reduces trial-and-error costs.
Supports design optimization for complex cast/molded components.
Aluminum Die Cast Products Gallery
Products
Automotive Parts
Use aluminum die casting to make tough, lightweight car parts
·engine blocks
·transmission cases
·wheel hubs
Consumer Electronics
Aluminum die casting is ideal for producing slender and thermally stable parts
·frames or casings for notebooks
·frames or casings for mobile phones
·frames or casings for cameras
Aerospace Components
Use aluminum die casting for the production of lightweight yet durable components
·aircraft brackets
·aircraft housings
·frames or casings for cameras
Industrial Machinery
Use aluminum die casting to make long-life components
·gearboxes
·pumps
·housings
Lighting Fixtures
Aluminum die casting creates aesthetically appealing enclosures with thermal conductivities for LED and other lighting applications
Aluminum Die Casting Material Options
High melting point + corrosion resistance (premium pricing).
Easy machinability, high ductility, and reliable wear resistance.
Heat-treatable with good machinability and castability.
Anti-soldering performance, excellent machinability & strength, and cost-effective.
Thermosets
Materials Gallery
View the hundreds of materials available at Protolabs through all of our service lines.
Quality Assurance
At Mastars, quality underpins every process—from tooling to standards. Our ISO 9001, ISO 14001 and IATF 16949 certifications ensure consistent excellence.
Advanced Inspection Equipment
Comprehensive Testing Procedures
Proven Quality Standards
Quick links
Technical video
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Manufacturing on Demand
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