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
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
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
T1 Samples As Fast As 3 Days
· Tight Tolerances as Low as +/- 0.003”
· Full-BOM Services Including Welding, Installation, & Assembly
· Ideal for Bulky, Complex, or High-Volume Parts
· No Minimum Order Quantity
· Post-Casting CNC Machining for Final Features
· Finishing Options: Chem Film, Anodizing, Plating, Powder Coat
· Inspection Reports With Every Order
· Certified Aluminum, Zinc, and Magnesium Alloys
· Material Certifications & CoCs Available
Aluminum Die Casting Material Options
✔️ A360
✔️ A380
✔️ ADC10
✔️ ADC12
Common Applications of Aluminum Die Casting
✔️ Automotive Parts: Engine Blocks, Transmission Cases, Wheel Hubs
✔️ Consumer Electronics: Frameworks or Casings for Mobile Phones, Notebooks, and Cameras
✔️ Aerospace Components: Aircraft Brackets, Aircraft Housings, and etc.
✔️ Industrial Machinery: Gearboxes, Pumps, Housings
✔️ Lighting Fixtures: Enclosures with Thermal Conductivities for LED and Other Lighting Applications
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
Professional testing equipment ensures precise measurement and verification: spectrometers analyze metal composition, coordinate measuring machines inspect complex 3D shapes, 2.5D instruments verify detailed features, and height gauges handle basic dimensions.
✔️ Comprehensive Testing Procedures
Parts undergo four key tests: material analysis, durability testing, corrosion testing, and functional testing—verifying composition compliance, resistance to harsh conditions, environmental durability, and proper sealing.
✔️ Proven Quality Standards
Over 90% of parts pass first article inspection on the first try. We offer free rework for any quality issues, and every unit undergoes full inspection before shipment.
Our Ideas Have Helped Clients Bring Hundreds Of Products To Market
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Choose Mastars, You'll Gain
We don't have MOQ, only 1pcs is according to high standard to make, we pursuit the product is perfect to every customer, from 1pcs to million,we are glad to witness and grow together with our customers, that make us proud.
Download Our Manufacturing Equipments List
We offer a one-stop processing service from prototypes and molds to machining and assembly, and are equipped with various models of processing equipments from major domestic and international companies, for CNC machining, injection molding, mold making, and sheet metal manufacturing. Download Now！
Our Production Capability
✔️ Able to achieve complex structures and tight tolerances
✔️ Short molding cycle, suitable for high-volume manufacturing
✔️ Excellent surface quality
Our Services
We don't have MOQ, only 1pcs is according to high standard to make, we pursuit the product is perfect to every customer, from 1pcs to million,we are glad to witness and grow together with our customers, that make us proud.
Industries We Serve
We don't have MOQ, only 1pcs is according to high standard to make, we pursuit the product is perfect to every customer, from 1pcs to million,we are glad to witness and grow together with our customers, that make us proud.
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