Cold Chamber Die Casting Manufacturer
Precision Cold Chamber Die Casting & Advanced Machining Solutions
Flexible Tooling Options to Optimize Your Initial Investment
Comprehensive One-Stop Service — Mold Design, Die Casting, CNC, Surface Finishing
Support Low to High Volume Production — Starting from 100pcs Scalable Production Capabilities
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Your Trusted Cold Chamber Die Casting Manufacturer in China - Precision Casting Solutions Tailored to Your Needs
IEC Mould specializes in advanced Cold Chamber Die Casting for high-quality aluminum and magnesium parts used in automotive, aerospace, and industrial applications. Our comprehensive in-house services include mold design, cold chamber casting, CNC machining, and surface finishing, ensuring full process control and seamless production. With our precise cold chamber process, you benefit from:
Superior mechanical strength and durability.
Excellent surface finish with minimal post-processing.
Consistent dimensional accuracy for tight tolerances.
Reduced porosity and internal defects for reliable performance.
Our state-of-the-art equipment and rigorous quality management guarantee stable, repeatable results across every batch — whether you require large structural components or intricate precision castings. Partner with IEC Mould to optimize your manufacturing workflow, minimize supplier risk, and receive cold chamber die castings that meet your exact specifications — delivered on time and within budget.
What is Cold Chamber Die Casting?
Cold Chamber Die Casting is a process in which molten metal, typically aluminum or magnesium alloys, is poured into a cold shot chamber and then injected into a steel mold under high pressure. Unlike hot chamber casting, the molten metal is not kept in the machine’s injection system, making this method ideal for metals with high melting points or those that react adversely with the injection mechanism.
The cold chamber process enables the production of complex, high-strength components with excellent surface finish and tight dimensional tolerances. It is widely used in automotive, aerospace, and industrial sectors for parts such as engine blocks, transmission cases, and structural components.
Cold Chamber Die Casting offers superior mechanical properties and reduced porosity compared to other casting methods, making it well-suited for critical applications that demand durability and precision.
Why Choose Cold Chamber Die Casting?
🧠 Engineers
Produces durable, high-strength parts for critical applications
- Supports complex geometries with tight dimensional tolerances
- Compatible with FEA simulations and mechanical testing
🕵️ Quality Control (QC) Professionals
- Stable process minimizing porosity and internal defects
- Full traceability with detailed inspection reports
- In-house X-ray, CMM, and pressure testing capabilities
💼 Procurement Teams
- Fast lead times with in-house tooling and machining
- Flexible MOQ starting at 100 pcs
- Competitive pricing for medium to large volumes
📦 Product Managers / Founders
- One-stop service from mold design to assembly
- Scalable from prototyping to mass production
- Faster time-to-market with expert DFM support
How Cold Chamber Die Casting Works?
Cold Chamber Die Casting is a manufacturing process used for metals with high melting points, such as aluminum, magnesium, and copper alloys. Unlike hot chamber systems, molten metal is not held inside the injection unit. Instead, it is transferred from a separate melting furnace into the “cold chamber” before injection. Here is a Step-by-Step Cold Chamber Die Casting Process：
Step 1: Mold Preparation & Preheating
The process begins with preparing the steel mold (die). The die is thoroughly cleaned to remove any residual metal or debris, then preheated to an optimal temperature — typically between 150°C and 250°C. Preheating helps to:
Reduce thermal shock and prevent cracking
Improve metal flow into thin and complex sections
Enhance casting surface finish and dimensional stability
Step 2: Molten Metal Melting in External Furnace
Unlike hot chamber casting, cold chamber die casting uses an external melting furnace because the alloys (such as aluminum, magnesium, and copper-based alloys) require higher melting points.
The selected alloy is melted at the precise temperature needed for fluidity.
The molten metal is maintained under controlled temperature to avoid oxidation and contamination.
Step 3: Metal Transfer into Cold Chamber Sleeve
A measured quantity of molten metal is ladled from the holding furnace into the cold chamber sleeve of the die casting machine.
Transfer is done quickly to prevent temperature loss.
This step isolates the molten metal from the injection mechanism, preventing damage from high melting temperatures.
Step 4: High-Pressure Injection into the Die Cavity
A hydraulic piston (plunger) pushes the molten metal from the cold chamber sleeve into the die cavity at extremely high pressure — up to 30,000 psi.
This rapid injection ensures complete mold filling, even in thin-wall and intricate areas.
The high pressure also improves part density and surface detail.
Step 5: Solidification Under Pressure
The molten metal cools and solidifies inside the die while the injection pressure is maintained.
Pressure prevents shrinkage porosity by feeding additional molten metal into the cavity as it solidifies.
Cooling time is carefully controlled for consistent mechanical properties.
Step 6: Die Opening & Part Ejection
Once the casting is solidified, the die opens, and ejector pins push the casting out of the mold.
The casting is inspected for obvious surface defects.
The die cavity is cleaned and lubricated before the next cycle.
Step 7: Trimming & Flash Removal
Excess material (flash, runners, gates) is removed by trimming presses or manual cutting.
This ensures the part is closer to its net shape and ready for finishing.
Step 8: CNC Machining & Finishing & Final Inspection
Critical surfaces are machined to meet tight tolerances.
Drilling, tapping, milling, and other secondary operations are performed as required.
- X-ray, leak test, CMM, dimensional reports, microstructure validation.
Key Advantages of Cold Chamber Die Casting
| Advantage | For Engineers | For Procurement Teams | For Quality Control (QC) |
|---|---|---|---|
| Handles High-Melting Alloys (Aluminum, Copper, Brass) | Enables use of stronger, wear-resistant alloys for structural parts. | Broadens product range to serve more industries and applications. | Stable inspection criteria across multiple alloy types. |
| High Dimensional Accuracy (±0.1 mm) | Ensures design tolerances for critical-fit components with minimal rework. | Reduces machining time and cost per part. | Faster dimensional verification during inspection. |
| Superior Surface Finish (Ra 1.6–3.2 μm) | Produces castings with minimal post-processing for aesthetics or coating. | Reduces finishing costs and speeds delivery to market. | Easier to detect and address surface defects early. |
| Large Part Capability | Allows production of larger, complex shapes in a single casting. | Reduces part count, assembly labor, and sourcing complexity. | Fewer joints mean fewer potential defect points. |
| Good Mechanical Properties | Supports load-bearing designs with high tensile and yield strength. | Expands into high-performance markets like automotive & aerospace. | Consistent performance during fatigue and stress tests. |
| Long Mold Life | Delivers repeatable results over many production cycles. | Lowers tooling replacement costs and improves ROI. | Reduces variation caused by tooling wear. |
| Wide Application Range | Flexibility to meet demands of automotive, industrial, and hardware sectors. | Simplifies multi-market sourcing from one supplier. | Uniform inspection procedures across diverse products. |
| Supports Medium to High Volumes | Ideal for production runs from thousands to millions of parts. | Balances cost efficiency with scalable output. | Maintains quality consistency over long production runs. |
Cold Chamber Die Casting vs Other Casting Methods
✅ Cold Chamber Die Casting is ideal for high-melting-point alloys (aluminum, copper, brass) that require excellent mechanical strength, good surface finish, and high dimensional accuracy — widely used for automotive, aerospace, and industrial applications.
| Feature | Cold Chamber Die Casting (CCDC) | Hot Chamber Die Casting | Gravity Die Casting | Sand Casting |
|---|---|---|---|---|
| Suitable Alloys | ✅ High-melting alloys (Al, Cu, Brass) | ❌ Low-melting alloys only (Zn, Mg) | ✅ Most non-ferrous alloys | ✅ Most metals |
| Filling Pressure | High (up to 1500+ bar) | Moderate to High | Gravity only | Gravity only |
| Porosity | ⚠️ Moderate (can be reduced with vacuum assist) | ❌ Higher risk | ⚠️ Moderate | ❌ High |
| Heat Treatment | ✅ T5/T6 Applicable | ❌ Often not possible | ✅ Yes | ✅ Yes |
| Surface Finish | ⭐⭐⭐⭐ (Smooth, Ra 1.6–3.2 μm) | ⭐⭐⭐⭐ | ⭐⭐ | ⭐ |
| Dimensional Accuracy | ⭐⭐⭐⭐ (±0.1 mm) | ⭐⭐⭐⭐ | ⭐⭐ | ⭐ |
| Part Size Capability | Medium to Large | Small to Medium | Medium to Large | Large |
| Ideal for | Structural parts, housings, brackets, engine components | Small, intricate, high-volume parts | Simple to medium-complexity shapes | Large prototypes or low-volume production |
Cold Chamber Die Casting Part Applications Across Industries
| Industry | Image | Typical Components | Why Cold Chamber Die Casting Fits |
|---|---|---|---|
| Heavy Machinery & Construction |  | Gearbox housings, hydraulic pump blocks, crane frames, transmission cases | Supports large, thick-wall aluminum, copper, or brass parts requiring high strength and durability for heavy-duty machinery. |
| Marine & Offshore Engineering | | Engine housings, propeller components, steering systems, offshore drilling equipment parts | Produces corrosion-resistant, structurally robust components suitable for harsh saltwater and offshore environments. |
| Agricultural Equipment | | Tractor transmission housings, combine gear covers, axle housings, hydraulic cylinder bodies | Ideal for rugged, high-load components that endure continuous stress and outdoor conditions over long periods. |
| Medical & Imaging Equipment | | MRI frames, X-ray table bases, medical pump housings, diagnostic enclosures | Enables precision casting of large, stable, and smooth-surfaced parts for sensitive medical instruments. |
| Power Generation & Energy | | Wind turbine gearbox housings, generator frames, switchgear enclosures, water turbine parts | Creates high-strength, large-scale components for renewable energy and conventional power systems with long service life. |
| Commercial & Industrial Products | | Outdoor lighting housings, heavy-duty tool frames, refrigeration components, pump housings | Provides durable, pressure-resistant components with excellent dimensional accuracy for industrial applications. |
| Transportation & Rail | | Train brake housings, engine blocks, suspension components | Supports high-strength, thick-walled components that meet strict safety and reliability standards for transport. |
| Electronics & Telecom | | Large electronic enclosures, base frames for telecom towers, heat sinks | Allows precise casting of stable, thermally conductive parts for sensitive electronic and communication equipment. |
| Defense & Security | | Armored vehicle parts, turret housings, missile launch system frames | Produces robust, high-precision components capable of withstanding extreme conditions and heavy mechanical stress. |
Materials We Use for Cold Chamber Die Casting
| Material | Key Features | Typical Applications | Why It Fits Cold Chamber Die Casting |
|---|---|---|---|
| Aluminum Alloys (A380, A383, ADC12, 6061, 7075) | Lightweight, high strength-to-weight ratio, corrosion-resistant, excellent thermal conductivity | Gearbox housings, pump blocks, automotive & aerospace structural components, electronic enclosures | Allows precise, smooth-surfaced, dimensionally stable large parts |
| Copper Alloys (C93200, C95400, C95800) | Excellent wear resistance, high thermal/electrical conductivity, corrosion-resistant | Electrical components, marine parts, hydraulic & pneumatic components | Withstands heavy mechanical and thermal stresses, ideal for durable high-load parts |
| Zinc Alloys (Zamak 3, Zamak 5, Zamak 7) | High ductility, excellent dimensional accuracy, low melting point for faster production | Medium-sized housings, decorative hardware, industrial fittings | Perfect for medium-strength parts with intricate details and tight tolerances |
| Magnesium Alloys (AZ91D, AM60B) | Extremely lightweight, good strength-to-weight ratio, excellent machinability | Automotive interior & structural components, electronic housings, aerospace parts | Reduces part weight without compromising strength, ideal for transportation & high-performance applications |
| Specialty Alloys (High-strength Al-Cu, Si-Al alloys) | Enhanced mechanical properties, improved corrosion & wear resistance | Aerospace, defense, or high-performance industrial equipment | Tailored solutions for extreme environments and demanding applications |
Common Technical Specifications – Cold Chamber Die Casting (CCDC)
- Filling Pressure: Cold chamber die casting typically operates at 30 to 150 bar of injection pressure, forcing molten metal into the mold cavity rapidly. This high-pressure process allows for complex geometries and thin walls while maintaining dimensional accuracy.
- Cycle Time: Cycle times for CCDC generally range from 30 to 90 seconds, depending on part size and complexity. Compared to LPDC, CCDC is much faster, making it ideal for high-volume production.
- Alloy Selection: Common alloys include ADC12, A380, and 383 aluminum, as well as ZA alloys and magnesium alloys. These materials provide excellent strength, thermal conductivity, and corrosion resistance.
- Wall Thickness: Cold chamber die casting can produce walls as thin as 1 mm for small parts, with consistent density and minimal shrinkage, supporting both structural and aesthetic requirements.
- Tolerances: Typical tolerances range from ±0.05 mm to ±0.15 mm, enabling high-precision components suitable for automotive, electronics, and machinery applications.
Common Challenges and Solutions – Cold Chamber Die Casting (CCDC)
- Porosity and Gas Entrapment: High-pressure injection can trap gas in the casting, leading to porosity.
- Solution: Use vacuum-assisted systems or proper venting, combined with degassing of molten metal and optimized gating design to reduce gas inclusion.
- Die Wear and Maintenance: High-pressure injection increases wear on dies, especially for hard-to-fill or abrasive alloys.
- Solution: Employ high-quality die steels, surface coatings, and regular maintenance schedules to extend die life and ensure consistent quality.
- Hot-Tearing and Shrinkage: Complex geometries or uneven cooling can lead to hot-tearing or shrinkage defects.
- Solution: Utilize advanced thermal simulation tools like MOLDFLOW to optimize mold design, cooling channels, and injection parameters.
- Surface Finish Variation: While CCDC produces generally smooth surfaces, rapid filling can sometimes create flow lines or minor blemishes.
- Solution: Apply secondary finishing processes such as polishing, anodizing, or powder coating to achieve the desired surface quality.
- Complex Part Geometry Challenges: Thin walls, deep ribs, or sharp corners can be difficult to fill completely.
- Solution: Optimize runner and gate design, control injection speed and pressure, and consider multi-step or sequential injection for intricate components.
Why Engineers and Buyers Trust Us
- ✅ Over 20 years of die casting experience
- ✅ In-house mold, casting, machining & finishing
- ✅ Certified under ISO 9001 / IATF 16949
- ✅ Fluent English technical support
- ✅ Real-time updates with photos/videos of production
- ✅ Strict project confidentiality & IP protection
How to Work With Us
- ✅ Send Us Your Drawing or Idea
- ✅ Receive Free DFM Feedback
- ✅ We Quote Within 24 Hours
- ✅ Rapid Prototyping or Tooling Starts
- ✅ PPAP or Sample Approval
- ✅ Mass Production & Global Delivery
Cold Chamber Die Casting Frequently Questions & Answers
What are the typical tolerances for Cold Chamber Die Casting parts?
CCDC parts typically achieve tolerances ranging from ±0.05 mm to ±0.15 mm, depending on size, geometry, and alloy type. These tight tolerances make cold chamber die casting ideal for precision components that require excellent fit, repeatability, and structural integrity.
How does Cold Chamber Die Casting differ from Hot Chamber Die Casting?
The main difference is the injection method and suitable alloys. Cold chamber die casting uses a separate injection chamber, making it ideal for high-melting-point metals like aluminum and magnesium, while hot chamber die casting is faster but only suitable for low-melting-point metals like zinc or lead. CCDC offers better control for complex, high-strength components.
What are common challenges in Cold Chamber Die Casting and how are they addressed?
Common alloys include A356, A357, 319, and magnesium AZ91, all of which support heat treatments like T5 and T6 to improve strength, hardness, and fatigue resistance—critical for demanding applications.
Can Cold Chamber Die Casting parts be post-processed?
Yes, CCDC components can undergo secondary operations such as CNC machining, surface finishing (polishing, anodizing, powder coating), heat treatment, and assembly. These post-processing steps enhance dimensional accuracy, mechanical performance, and aesthetic appearance, meeting the requirements of demanding industries.
What is the maximum wall thickness achievable in Cold Chamber Die Casting?
Cold chamber die casting can produce wall thicknesses ranging from 1 mm to 10 mm, depending on part size, alloy, and mold design. Uniform density and minimal shrinkage ensure high-quality structural components even for thin walls.
How fast is the production cycle in Cold Chamber Die Casting?
CCDC typically has cycle times between 30 and 90 seconds, depending on part complexity and size. This rapid production makes it suitable for high-volume manufacturing while maintaining excellent precision and surface finish.
What surface finishes can be achieved on Cold Chamber Die Casting components?
CCDC parts can achieve smooth and precise surface finishes, suitable for aesthetic and functional applications. Secondary finishes include polishing, anodizing, powder coating, and painting, depending on the customer’s requirements.
