In the modern manufacturing industry, the ability to efficiently mass-produce precision metal components with excellent surface quality is critical. High Pressure Die Casting (HPDC) is a widely used near-net-shape forming process that combines speed, accuracy, and design flexibility. This article provides a detailed overview of HPDC, including the process, core advantages, typical applications, and technical trends—helping engineers and decision-makers understand why it has become a preferred choice across industries.
High Pressure Die Casting is a manufacturing method that involves injecting molten or semi-solid metal alloys into a steel mold cavity at very high pressure (typically 20–200 MPa). The metal solidifies under pressure, enabling the creation of components with complex geometries and high dimensional accuracy.
Depending on the casting equipment, HPDC is categorized into hot chamber and cold chamber die casting.
· Cold chamber die casting is used for metals with high melting points such as aluminum and magnesium.
· Hot chamber die casting is suitable for low melting point alloys like zinc and lead.
Most modern aluminum die casting factories use horizontal cold chamber die casting machines, which are highly automated and suitable for large-scale production.
The HPDC cycle consists of the following key steps:
1. Mold Preparation
The mold is preheated and sprayed with a release agent to ensure easy ejection and prolong mold life.
2. Injection of Molten Metal
Molten metal is poured into the shot sleeve and injected into the mold cavity at high speed and pressure (15–70 m/s).
3. Pressurization and Solidification
Pressure is maintained after filling to eliminate shrinkage and improve density.
4. Cooling and Ejection
The mold’s internal cooling system rapidly cools the part. After solidification, the die opens and the part is ejected.
5. Trimming and Post-Processing
Excess materials such as flash and sprue are removed. Some parts may undergo secondary machining or surface treatment.
The entire cycle can be completed in seconds, making HPDC ideal for high-volume production.
1. High Productivity
HPDC offers extremely short cycle times compared to gravity or low pressure casting, supporting 24/7 mass production.
2. Superior Dimensional Accuracy
Parts can achieve dimensional tolerances up to IT9 and surface roughness as low as Ra 0.8–1.6 µm, reducing or eliminating the need for machining.
3. Thin-Wall Capabilities
Wall thicknesses as low as 0.4 mm are achievable, reducing product weight and enabling lighter, more efficient designs.
4. Complex Geometry in One Shot
Intricate shapes and internal features can be formed directly in the mold, including embedded inserts, reducing assembly time.
5. Long Mold Life
Although die tools are expensive, their longevity over many cycles helps amortize cost and reduce per-part expenses.
6. High Material Utilization
Due to near-net shaping and recyclability of excess material, material usage can exceed 95%.
Automotive Industry
HPDC is used to manufacture engine blocks, transmission housings, cross members, brackets, and other structural aluminum or magnesium parts.
Medical Devices
HPDC provides lightweight, corrosion-resistant enclosures and components for surgical tools, pumps, and imaging devices.
Aerospace Sector
With the ability to produce precision and lightweight parts, HPDC is widely applied in aircraft engine components and mounting structures using aluminum, zinc, and magnesium alloys.
Electronics and Telecommunications
Ideal for producing heat sinks, housings, and EMI shielding parts with excellent thermal and dimensional performance.
· Injection Speed and Pressure
Critical for proper mold filling. Too fast may trap air, too slow may cause cold shuts.
· Mold Temperature
Low mold temperature may result in incomplete fills; too high may lead to soldering and mold damage.
· Holding Pressure and Time
Ensures complete filling and compensates for shrinkage during solidification.
· Alloy Composition and Melt Temperature
Affects fluidity and defect formation. Overheating can introduce oxides; underheating reduces fill quality.
| Defect | Cause | Solution |
| Porosity | Air entrapment | Optimize venting and injection curve |
| Cold Shuts | Inadequate melt flow or speed | Raise melt temperature and injection speed |
| Soldering | Poor mold coating or overheat | Maintain mold surface, apply release agent |
| Warping | Mold deformation or uneven temp | Calibrate machine, monitor temperature control |
· Vacuum Die Casting: Reduces porosity and improves density for heat-treatable parts.
· Digital Monitoring: Real-time tracking of injection speed, pressure, and mold temperature.
· Advanced Alloys: Use of high-strength, heat-resistant alloys like AlSi10MnMg.
· Giga Casting: One-piece die casting of large structural parts, especially for electric vehicles.
EDT Diecasting Technology (Suzhou) Co., Ltd. is an Italian-invested enterprise specializing in the production of aluminum and zinc alloy die casting parts. With a registered capital of €1.345 million and a workforce of 120, our facility is located in the scenic Suzhou High-tech Zone, covering 9,000 m².
We are equipped with advanced hot and cold chamber machines, multi-slide systems, vacuum casting technology, and closed-loop control systems. Our products are widely used in automotive parts, furniture hardware, electronics, telecommunications, and construction equipment.
EDT holds ISO 9001 and IATF 16949 certifications, and has been recognized as a Suzhou Innovative SME in 2022 and a Suzhou High-Tech SME in 2023. By 2023, we have obtained 21 patents, including 2 invention patents, reflecting our commitment to high-tech innovation and quality manufacturing.
Looking for a reliable aluminum die casting factory? EDT offers efficient, high-precision, and cost-effective die casting solutions tailored to your industry needs. Contact us to learn more.
Hotline
0512-67371602
E-mail：sales@edt-china.cn
Add：West Building, 66 Songshan Road, Suzhou New District, P.R. China
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