Custom Brass Die Casting Services
Looking for durable, corrosion-resistant Brass Die Casting solutions or want to understand Brass Die Casting pricing? As a professional Brass Die Casting supplier and trusted manufacturing partner, IEC MOULD delivers high-precision, high-strength, and wear-resistant brass casting technology tailored to your application. Whether you need complex fittings, threaded components, plumbing parts, electrical connectors, or decorative hardware, our brass expertise and scalable production capabilities ensure stable quality, dimensional accuracy, and long-term performance — contact us today!
±0.01mm
Tolearance
20+
Years Experience
20 Day
Die Casting Samples Delivered
Certifications
ISO 9001 & IATF 16949
Our Brass Casting Services
IEC MOULD provides full-service copper die casting solutions designed to deliver high-strength, corrosion-resistant, and dimensionally stable components for demanding applications. From design engineering to final assembly, we help customers achieve superior performance while maximizing brass’s unique advantages in conductivity, wear resistance, and long-term durability..
- Custom Brass Component Design: We design brass parts with complex shapes, precise threads, sealing features, and decorative details to meet your functional and aesthetic requirements.
- Engineering & Moldflow Simulation: DFM and moldflow analysis help reduce defects, improve metal flow, and ensure stable brass casting performance.
- Precision Tooling & Mold Making: Our in-house team builds durable brass die casting molds with optimized gating, venting, and cooling for consistent part quality.
- CNC Machining & Finishing: Accurate drilling, threading, polishing, and surface finishing ensure high precision and smooth, assembly-ready brass components.
- Surface Treatment Options: Polishing, nickel/chrome plating, passivation, sandblasting, and protective coatings enhance wear resistance and appearance.
- Assembly Support: We offer insert installation, sealing features, and sub-assembly services to deliver ready-to-use brass parts.
- Quality Testing: Dimensional checks, leak/pressure testing, hardness testing, and surface inspection ensure every brass part meets your standards.
IEC Mould's Brass Alloy Die Casting Capabilities
| Details | Specifications |
|---|---|
| Dimensional Accuracy for Brass Alloy Casting Components | Our brass die cast parts achieve tight tolerances of ±0.03 mm, and up to ±0.01–0.02 mm after CNC machining—ideal for precision copper-alloy components, threaded fittings, and high-accuracy hardware assemblies. |
| Minimum Wall Thickness for Brass Casted Parts | Thin-wall sections typically range from 1.0–2.0 mm, depending on part geometry and tooling design. Brass alloy’s excellent fluidity supports stable, thin-wall structures for both industrial and decorative applications. |
| Uniform Wall Structure Requirement | To maintain proper brass flow and reduce shrinkage or internal porosity, wall-thickness ratios between adjacent areas are kept around 1:1.3 to 1:1.8, ensuring consistent casting quality. |
| Fine Details, Threads & Inserts | Small holes (≥1.0 mm), detailed threads, logos, and insert features can be cast directly into brass components, reducing secondary machining and improving production efficiency. |
| Draft Angle for Brass Casting Ejection | Typical draft angle: 1°–2°, adjustable for cosmetic surfaces or high-precision areas. Brass’s casting behavior supports complex shapes and detailed contours. |
| Mold Durability for Copper-Alloy Casting | Brass casting molds generally achieve 50,000–200,000 cycles, depending on alloy type, temperature control, and part complexity—ideal for medium to high-volume brass component production. |
| Surface Finish Quality | As-cast brass surfaces typically reach Ra 1.6–3.2 µm, suitable for polishing, nickel/chrome plating, passivation, sandblasting, or decorative finishing with minimal preparation. |
| Minimum Production Volume | Flexible production starting from 300 pcs, making it suitable for custom copper-alloy parts, plumbing fittings, electrical connectors, mechanical components, and hardware products. |
| Production Schedule / Lead Time | Mold fabrication + first article sampling: 25–35 days, depending on brass alloy selection, design complexity, and finishing requirements. Optimized cooling ensures efficient brass pressure-casting cycles. |
Brass Parts We Manufactured
These brass alloy cast components highlight our capability in producing high-precision, corrosion-resistant parts with detailed features and stable dimensional performance. From plumbing fittings and valve bodies to electrical connectors and decorative hardware, each component reflects our commitment to accuracy, durable copper-alloy metallurgy, and consistent quality in brass pressure casting manufacturing.
Brass Lighting Part
Brass Lighting Part
Brass Fitting Part
Brass Hardware Part
Brass Locking Part
Engineering Part
Choosing the Right Brass Alloy for Your Die Cast Components
Selecting the proper brass alloy is essential to achieving the optimal balance of strength, corrosion resistance, surface finish, and production efficiency. Whether your project requires precision brass die cast components, high-pressure brass metal casting, or durable copper alloy die casting, IEC MOULD’s engineering team evaluates your mechanical requirements, usage environment, and production scale to recommend the most suitable alloy for high-quality brass pressure die casting performance.
| Alloy Grade | Key Characteristics | Typical Applications | Why It Excels in Brass / Copper Alloy Die Casting |
|---|---|---|---|
| CuZn39Pb3 (CW614N) | Excellent machinability, strong mechanical properties, smooth as-cast finish, and consistent castability. | Plumbing fittings, connectors, industrial hardware | Perfect for high-volume brass casting with tight tolerances and efficient CNC finishing—ideal for cost-effective brass die cast components. |
| CuZn40 (CW509L) | Lead-free composition, strong corrosion resistance, good strength, RoHS/REACH compliant. | Drinking-water systems, sanitary hardware, eco-compliant parts | Ideal for environmentally friendly copper alloy casting where safety compliance and mechanical reliability are critical. |
| CuZn30 (CW505L) | High ductility, excellent corrosion resistance, stable flow for complex geometries. | Electrical housings, decorative elements, general hardware | Best for intricate brass alloy die casting projects requiring fine details, smooth surfaces, and dimensional stability. |
| CuZn36Pb2As (CW602N – DZR Brass) | Exceptional dezincification resistance; strong performance in hot-water and high-pressure environments. | Valve bodies, pump components, water system fittings | A top choice for brass pressure die casting in fluid-control applications needing long-term reliability and sealing integrity. |
| CuZn21Si3P (Silicon Brass) | High strength, excellent wear resistance, improved castability, reduced lead content. | Lock bodies, mechanical components, structural hardware | Excels in heavy-duty copper casting applications where durability, precision, and surface quality are essential. |
Custom Brass Casting Manufacturers and Suppliers
IEC MOULD is a professional Brass Die Casting manufacturer and supplier, specializing in producing high-strength, corrosion-resistant copper alloy die cast components for plumbing, electrical, hardware, automotive, and industrial equipment. With our in-house tooling center, dedicated brass pressure die casting cells, multi-axis CNC machining, and integrated finishing processes, we provide a complete turnkey solution—from custom design and prototyping to mass production and assembly. We deliver components with:
- Precision Dimensional Control: Consistent accuracy, clean edges, and stable thin-wall forming for precision brass die cast parts, reducing secondary machining and production costs.
- Durable Copper Alloy Performance: Excellent corrosion resistance, structural strength, and wear durability—ideal for fluid-control systems, mechanical components, and long-life industrial applications.
- Superior Surface Finish & Aesthetic Quality: Brass alloys offer natural luster and excellent surface uniformity, enabling high-quality plating, polishing, coating, and decorative finishing.
- Efficient Production & Reliable Lead Times: Optimized tooling design, flexible batch capability, and streamlined brass alloy casting operations ensure fast delivery and consistent production efficiency.
Supported by ISO 9001 & IATF 16949 certifications, rigorous inspection standards, and advanced measurement systems, IEC MOULD ensures stable quality, competitive pricing, and dependable global supply. Choose IEC MOULD for high-performance brass and copper alloy die casting solutions engineered to meet modern requirements for precision, durability, and long-term reliability.
Why Choose IEC MOULD for Your Copper Alloy Die Casting Parts?
1. You Get Components That Perform Reliably in Real-World Conditions
Customers choose IEC because our brass and copper alloy die castings deliver high strength, precise dimensions, and excellent conductivity where it matters most—electrical systems, heat-transfer modules, precision valves, connectors, and structural fittings. Every part is engineered to maintain stable tolerances, dimensional accuracy, and long-term material integrity, even under high temperature, high pressure, or corrosive environments.
What this means for you: fewer product failures, better field performance, and a more durable, reliable final product.
2. Reduced Quality Risks Through Verified Production
Predictable quality is critical for copper alloy components. IEC’s production process, certified to ISO 9001 & IATF 16949, includes CMM inspection, X-ray analysis, leak testing, conductivity measurement, and metallographic verification. This ensures:
- Consistent quality across all batches
- Full traceability for every shipment
- Lower risk of dimensional or structural defects
- Confidence that all parts meet strict specifications
What this means for you: fewer complaints, less rework, and smoother assembly downstream.
3. You Get Engineering Support That Reduces Cost and Prevents Design Errors
IEC collaborates with your team to optimize designs, improve manufacturability, and reduce machining requirements. Our services include DFM reviews, moldflow simulation, copper alloy selection, and optimized gating and cooling designs, helping prevent casting defects and porosity issues.
What this means for you: better-designed parts, lower tooling risk, and significantly reduced production costs over the lifetime of the product.
4. You Receive Faster Delivery, Lower Total Cost, and a Smoother Supply Chain
Our fully in-house workflow—mold design, tooling, die casting, CNC machining, finishing, and inspection—reduces delays, miscommunication, and coordination issues. This provides:
- Shorter lead times for tooling and revisions
- Stable, repeatable output for medium-to-high volume production
- Lower total cost through optimized casting accuracy
- One reliable supplier from prototype to full-scale production
What this means for you: predictable delivery, efficient project flow, and a dependable long-term partner.
Other Die Casting Metals Services You May Looking for
Copper Casting Parts Frequently Questions & Answers
Which copper alloys are suitable for die casting?
Brass, bronze, and other copper alloys are commonly used, selected based on corrosion resistance, mechanical strength, wear resistance, or electrical conductivity.
What is the minimum wall thickness achievable in brass die casting?
Thin-wall sections as low as 1 mm are possible, depending on alloy selection and mold design.
What tolerances can be achieved in copper alloy die castings?
Typical tolerances range from ±0.05 mm to ±0.1 mm, with tighter tolerances achievable after CNC machining or finishing.
Can brass and copper alloy die cast parts withstand high temperature or corrosion?
Selected copper alloys provide high-temperature resistance and excellent corrosion performance, suitable for heat-transfer components, valves, and industrial equipment.
What surface finishes can be applied to copper alloy die cast parts?
Surfaces can be polished, plated, painted, powder coated, or finished for decorative and functional requirements.
What temperature is needed to cast brass?
Brass alloys typically require melting temperatures between 900°C and 950°C (1650°F–1740°F), depending on the specific alloy composition. Maintaining proper temperatures ensures smooth flow, complete mold filling, and minimal porosity.
Can brass be die casted?
Yes, brass can be die cast using high-pressure die casting methods. Brass alloys are suitable for producing complex geometries, thin walls, and precise features with good dimensional accuracy, corrosion resistance, and mechanical strength. Proper alloy selection and mold design are essential to achieve consistent quality and minimal porosity.
What is Brass Die Casting?
Brass die casting is the process of injecting molten brass or copper alloy into a precision steel mold under high pressure to produce parts that are durable, precise, and ready for real-world use. Brass cast components are valued for corrosion resistance, wear resistance, excellent conductivity, and mechanical strength, making them perfect for plumbing fittings, valves, electrical connectors, heat-transfer modules, and decorative hardware.
Despite being tough and long-lasting, brass flows smoothly in molten form, filling thin walls, deep ribs, and intricate features with ease. That’s why engineers love using copper alloy die castings to replace multi-piece assemblies with single integrated parts—fewer screws, fewer assembly steps, and far fewer headaches.
Another big advantage is design freedom. Optimized mold design and precise casting parameters allow tight tolerances, consistent quality, and efficient medium-to-high-volume production. Whether it’s precision connectors, structural brackets, or heat-resistant housings, brass die casting delivers reliability without compromise.
So what is brass die casting, really?
It’s the go-to solution when a project needs strong yet precise, complex yet reliable, and high-performance yet cost-effective components. Think of it as getting the best of strength, durability, and design flexibility all in one component—except this time, the “magic” is a high-quality brass cast part that can handle everything thrown at it… and then some.
Types of Brass & Copper Alloy Die Casting
Brass and copper alloy castings can be produced using several die casting methods. Each method affects part quality, dimensional accuracy, cycle time, and cost, helping engineers and buyers choose the optimal solution for thin-walled parts, complex geometries, or high-volume manufacturing.
High Pressure Brass Die Casting
High-pressure brass die casting injects molten brass into precision molds under high pressure, delivering fast cycles, excellent repeatability, and tight tolerances. Because the molten alloy is handled in a controlled system, oxidation is minimized and flow consistency is high, making this method ideal for small, thin-walled, high-volume components like connectors, valves, and decorative fittings.
Limitations: High-pressure systems have higher equipment costs and may be less suitable for very large or thick-walled structural parts.
High-Pressure Copper Alloy Die Casting
For medium-to-large copper alloy components, high-pressure casting melts the alloy in a separate furnace and injects it under controlled high pressure. This method accommodates all commercial copper alloys and supports larger, stronger parts with low porosity, making it ideal for housings, brackets, industrial assemblies, and load-bearing components.
Advantages: Provides excellent dimensional stability, tight tolerances, and consistent mechanical performance.
Trade-offs: Cycle times are slower than small-part high-pressure casting, but overall part quality and structural integrity are superior.
Low-Pressure Brass or Copper Alloy Casting
Low-pressure casting injects molten alloy at a reduced pressure to produce dense, high-integrity parts, particularly for medium-to-large hollow components or parts with complex internal features.
Advantages: Improved material density and reduced porosity.
Limitations: Production is slower than high-pressure casting, best suited for moderate-volume projects.
Gravity or Pressure-Assisted Copper Alloy Casting
This method relies on gravitational flow of molten alloy, optionally assisted by low pressure, to produce large, thick-walled components. It is commonly used for structural frames, housings, and heavy industrial parts.
Advantages: Lower tooling cost and simpler process.
Limitations: Surface finish and dimensional precision are generally lower than high-pressure casting.
Choosing the Right Brass or Copper Alloy Casting Method
- Small, thin-walled, high-volume components → High-Pressure Brass Die Casting
- Medium-to-large structural parts → High-Pressure Copper Alloy Die Casting
- Hollow or internally complex parts → Low-Pressure Brass/Copper Alloy Casting
- Large, thick-walled components → Gravity or Pressure-Assisted Copper Alloy Casting
At IEC Mould, careful evaluation of alloy type, part geometry, wall thickness, production volume, and mold design ensures the selected method delivers optimal performance, tight tolerances, cost-efficiency, and consistent quality for every brass die casting or copper alloy casting project.
Brass & Copper Alloy Properties
| Alloy | Density | Yield Strength | Elongation | Elastic Modulus | Melting Temperature | Comments / Die Casting Suitability |
|---|---|---|---|---|---|---|
| C36000 (Free-Cutting Brass) | 8.4 g/cm³ | 345 MPa | 15% | 100 GPa | 1640–1700 °F (890–925 °C) | Excellent machinability, good fluidity, ideal for small precision castings. |
| C37700 (Bearing Brass) | 8.5 g/cm³ | 345 MPa | 15% | 100 GPa | 1620–1680 °F (880–915 °C) | High wear resistance, good corrosion resistance, suitable for high-volume die casting. |
| C46400 (High Strength Brass) | 8.5 g/cm³ | 380 MPa | 8% | 110 GPa | 1630–1700 °F (890–925 °C) | Stronger than C36000, suitable for structural die-cast components. |
| C69300 (Copper-Zinc-Nickel Alloy) | 8.6 g/cm³ | 310 MPa | 12% | 110 GPa | 1650–1720 °F (900–940 °C) | Excellent corrosion resistance, commonly used for valves, fittings, and marine applications. |
| C85400 (Copper-Silicon Alloy) | 8.7 g/cm³ | 290 MPa | 10% | 110 GPa | 1700–1770 °F (927–963 °C) | High fluidity and corrosion resistance, suitable for complex thin-walled die castings. |
| C93200 (Copper-Tin-Lead Alloy) | 8.6 g/cm³ | 300 MPa | 12% | 110 GPa | 1650–1720 °F (900–940 °C) | Good corrosion resistance, used for bushings, gears, and high-precision components. |
Why Choose Custom Brass Alloy Casting?
Brass and copper alloy die casting stands out when components must combine strength, conductivity, corrosion resistance, and dimensional accuracy. These alloys provide performance advantages that lighter metals like magnesium or aluminum cannot match, making them ideal for electrical connectors, heat-transfer modules, valves, precision fittings, and structural assemblies.
1. High Strength & Structural Integrity
High-Pressure Brass Die Casting and Copper Die Casting produce parts with excellent mechanical strength and durability, capable of supporting load-bearing housings, brackets, and precision components.
Their robust structure ensures long-term performance in demanding environments, including industrial, automotive, and electrical applications.
2. Superior Electrical & Thermal Performance
Copper alloys naturally provide high electrical and thermal conductivity, making Copper Die Casting ideal for motors, connectors, power electronics, and heat sinks.
Brass die casting offers a good balance of corrosion resistance and conductivity, suitable for plumbing fixtures, valves, and decorative hardware.
3. Excellent Processability for Complex & Thin-Walled Parts
Both High-Pressure Brass Die Casting and Low-Pressure Brass Die Casting support intricate geometries, thin walls, deep ribs, and integrated features.
Molten alloys flow efficiently, allowing multiple components to be consolidated into a single die casting, reducing assembly time, fasteners, and overall part count.
4. Corrosion & Wear Resistance
Brass and copper alloys provide natural corrosion resistance in water, air, and chemical environments.
High-strength die cast alloys maintain wear resistance under repetitive stress, making them suitable for bushings, bearings, and mechanical assemblies.
5. High-Volume Production Efficiency
Die casting brass and copper alloys ensures:
- Consistent dimensional accuracy across batches
- Fast injection and solidification cycles for medium-to-high volume orders
- Reduced secondary machining operations compared to solid billet processing
This translates into lower production costs and reliable, repeatable quality.
6. Precision Machining & Secondary Operations
Even with near-net-shape die castings, brass and copper alloys can be CNC machined with high precision for threads, inserts, and critical tolerances.
The excellent machinability reduces tool wear, lowers costs, and speeds up turnaround time for finished components.
How Brass & Copper Alloy Die Casting Works
As a dedicated brass and copper alloy die casting manufacturer, IEC Mould understands that working with copper alloys is different from magnesium or aluminum. Copper’s higher density, slower solidification, and sensitivity to porosity require precise process control, specialized equipment, and experienced engineering judgment.
Below is the typical six-step brass and copper alloy die casting workflow used by advanced foundries. It highlights what truly matters from the viewpoints of engineers, procurement teams, and quality control departments.
Step 1: Alloy Melting & Preparation
Copper and brass ingots (e.g., C36000, C37700, C46400) are melted in a controlled furnace to maintain stable composition and fluidity. Proper preparation ensures:
- Smooth flow into thin walls, ribs, and detailed features
- Low porosity and minimal shrinkage
- Consistent mechanical strength and conductivity
Step 2: Die & Mold Preparation
The steel die is preheated to prevent thermal shock and coated with a release agent suitable for copper alloys. Key points include:
- Optimized venting and gating for high-pressure or low-pressure brass die casting
- Cooling channel design for controlled solidification
- Accommodation for inserts, thin walls, and fine features
Step 3: High-Pressure or Low-Pressure Casting
Molten copper alloy is injected under high pressure for thin-walled, high-volume parts or under low pressure for larger, hollow, or structurally demanding components. Process highlights:
- Precise control of injection speed and pressure
- Minimization of turbulence and gas entrapment
- Consistent dimensional accuracy and repeatable tolerances
Step 4: Cooling & Solidification
Copper and brass solidify more slowly than magnesium, so controlled cooling is critical. Effective solidification ensures:
- Reduced warping or shrinkage
- Uniform microstructure for strength, wear resistance, and conductivity
- Reliable results for medium-to-high-volume production
Step 5: Trimming & Surface Finishing
After ejection, runners, gates, and flash are removed. Magnesium’s excellent machinability allows for smooth and efficient secondary processing. Common finishing options include:
- CNC machining for ultra-precise features
- Shot blasting or tumbling for uniform surface texture
- Chromate conversion coating, anodizing, or painting for corrosion resistance
- Final assembly of magnesium housings or mechanical components
Step 6: Quality Inspection & Testing
Because magnesium parts are often structural, every batch undergoes strict inspection to ensure mechanical reliability and dimensional accuracy. Typical tests include:
- X-ray / CT scanning for internal porosity and structural integrity
- CMM measurement for dimensional and geometric accuracy
- Mechanical testing for tensile strength, elongation, impact resistance
- Corrosion resistance testing for coatings or protective treatments
- Surface inspection for cosmetic or functional requirements
Advantages of Brass Die Casting
Brass and copper alloy die casting is widely used for high-performance, precise, and durable components in automotive, electrical, industrial, and electronic applications. IEC Mould specializes in High-Pressure Brass Die Casting, Low-Pressure Brass Die Casting, and general Copper Die Casting, delivering reliable brass die cast components with optimized performance.
| Advantage | For Engineers | For Procurement Teams | For Quality Control (QC) |
|---|---|---|---|
| High Strength & Structural Integrity | Ensures robust performance in connectors, valves, housings, and mechanical fittings | Reduces material failure risk and warranty claims | Maintains consistent mechanical properties in all brass die cast components |
| Excellent Electrical & Thermal Conductivity | Ideal for heat sinks, power distribution blocks, and electronic housings | Minimizes additional treatments for conductivity or heat dissipation | Simplifies QC testing for electrical resistance and thermal performance in copper die cast parts |
| Precision & Dimensional Accuracy | Supports thin-walled, complex geometries with tight tolerances | Reduces scrap, secondary machining, and production cost | Ensures stable, repeatable quality in both high-pressure brass die casting and low-pressure brass die casting |
| Corrosion & Wear Resistance | Suitable for long-life components in corrosive or harsh environments | Extends product lifespan, lowering replacement and maintenance costs | Allows consistent inspection for corrosion, wear, and surface integrity |
| High-Pressure Brass Die Casting Efficiency | Produces dense, intricate parts at high volume with fast cycles | Shorter lead times reduce per-unit cost | Achieves minimal porosity and repeatable high-quality components |
| Low-Pressure Brass Die Casting Flexibility | Ideal for medium-to-large hollow or structurally demanding parts | Supports efficient sourcing and medium-volume production | Enhances material integrity and surface finish for QC compliance |
| Machinability & Post-Processing | Easy threading, drilling, and assembly for complex brass die cast components | Reduces secondary machining time and cost | Enables precise measurement and defect-free finishing |
| Design Flexibility & Part Consolidation | Allows multi-feature integration, reducing assembly steps and part count | Simplifies supply chain and improves production efficiency | Fewer assembly steps mean lower risk of assembly-related defects |
| Sustainability & Recyclability | Copper and brass scrap can be re-melted without performance loss | Supports eco-friendly and cost-efficient sourcing | Ensures consistent alloy composition and repeatable quality in recycled copper die cast parts |
Disadvantages of Brass Casting
Brass and copper die casting offer strength, durability, and excellent conductivity, but like any engineering material, they have limitations that must be considered. Early understanding of these factors helps ensure reliable design, efficient production, and consistent quality.”
| Disadvantage | For Engineers | For Procurement / QC Teams |
|---|---|---|
| Higher Melting Temperature | Copper and brass alloys require higher melting points, which can affect tooling wear and thermal control | Increased energy consumption and potential higher mold maintenance costs |
| Porosity Risk in Complex Parts | Intricate geometries or thick-to-thin transitions may develop porosity if injection or pressure is not optimized | QC must inspect density and internal defects; may require rework or adjustments |
| Limited Thin-Wall Capability | Very thin sections can be challenging for some copper/brass alloys compared to magnesium or zinc | May require design adjustment or slower injection to maintain quality |
| Slower Cycle Time for Large Parts | High thermal mass and slower cooling for thick or large components | Longer production runs can impact delivery schedules and cost per part |
| Higher Cost for Low Volume | Specialized tooling and slow cycles may not be economical for small batches | Procurement must balance cost, quality, and minimum order quantities |
| Post-Processing Requirements | Machining, deburring, or surface finishing may be needed for tight tolerances or smooth surfaces | Adds extra time and cost in assembly or coating stages |
| Alloy Limitations for Certain Applications | Some copper alloys may not provide desired corrosion resistance, wear properties, or conductivity | Engineers may need to specify coatings or alternative alloys, increasing material cost |
Copper & Brass Die Casting vs Other Die Casting Metals
Copper and brass die casting (including high-pressure brass die casting) provides engineers with exceptional strength, conductivity, and corrosion resistance in precision components. Its unique combination of high density, dimensional stability, and thermal/electrical conductivity allows complex geometries, thin walls, and functional features—such as ribs, bosses, threads, and heat-dissipating elements—to be integrated directly into a single part. This reduces secondary machining, assembly steps, and production complexity while maintaining long-term performance and reliability.
Compared to other die casting metals, copper and brass alloys are ideal for applications requiring mechanical robustness, wear resistance, and electrical or thermal conductivity. Fast filling under high-pressure die casting ensures tight tolerances, low porosity, and consistent quality for connectors, valves, housings, fittings, and electrical components.
At IEC Mould, engineers support copper and brass die casting with detailed DFM reviews, mold flow analysis, and alloy selection guidance. By understanding copper’s advantages relative to magnesium, aluminum, and zinc, informed decisions can be made to optimize cost, performance, and manufacturability.
| Property | Copper / Brass Alloys (Cu-Zn) | Magnesium (Mg) | Aluminum (Al) | Zinc (Zn) |
|---|---|---|---|---|
| Weight | Heavy – used where mass, stability, or wear resistance is required | Extremely light – ideal for handheld, portable, and weight-sensitive components | Very light – suitable for large parts | Moderate – provides solid feel |
| Strength & Toughness | Very high – ideal for wear-critical, load-bearing, and structural components; excellent corrosion and fatigue resistance | Moderate to high – excellent strength-to-weight ratio; supports thin-wall, load-bearing parts | High – strong but can be brittle in thin sections | High – strong and impact-resistant for small mechanisms |
| Dimensional Precision | Good – stable for medium to complex geometries; excellent for thin walls under controlled high-pressure die casting | Very good – stable for thin walls and complex geometries with proper tooling | Very good – suitable for most precision applications | Excellent – fine detail and high accuracy |
| Surface Finish | Excellent – naturally smooth, corrosion-resistant; can be polished or plated for aesthetics | Good – usually requires chromate, anodizing, or painting; smooth finish achievable | Good – can be anodized or painted | Superior – can be polished, plated, or coated |
| Thermal Resistance | Excellent – high thermal tolerance and conductivity; suitable for heat sinks, connectors, and valves | Moderate – dissipates heat well; performance drops above 120–150°C | Excellent – performs well in high-heat applications | Limited – loses strength above 150°C |
| Electrical & Thermal Conductivity | Very high – ideal for electrical connectors, thermal components, and EMI shielding | Low to moderate – not ideal for conductivity-critical applications | Moderate – suitable for some electrical/thermal applications | Low – mainly mechanical applications |
| Production Efficiency | Moderate – high melting point requires precise high-pressure die casting; tooling wear higher, but repeatable quality | Moderate to high – rapid solidification allows thin-wall features; oxidation requires careful handling | High – efficient for medium-to-large components | Outstanding – low melting point enables fast cycles and long tool life |
| Cost Efficiency | Lower – higher raw material and energy cost; specialized tooling required; offset by performance, durability, and reduced maintenance | Moderate – higher material cost than aluminum, specialized tooling required, but weight savings offset cost | High – good balance of cost and performance | Excellent – minimal waste, fast cycles, long tool life |
| Typical Applications | Electrical connectors, precision valves, plumbing fittings, decorative hardware, marine components, heat-transfer modules | Automotive brackets, EV housings, aerospace structures, handheld electronics, precision casings | Engine covers, structural housings, heat sinks, large frames | Small gears, connectors, locks, hinges, decorative components |
Copper & Brass Die Casting Part Applications Across Industries
Copper and brass die cast parts are widely used where mechanical strength, corrosion resistance, thermal and electrical conductivity, and dimensional precision are required. These alloys allow intricate geometries, thin-wall designs, and consistent tolerances under high-pressure die casting, producing ready-to-use components that perform reliably in demanding industrial, automotive, electronics, and consumer applications.
| Industry | Typical Components | Why Copper & Brass Die Casting Fits |
|---|---|---|
| Automotive & EV | Engine brackets, connector housings, valve bodies | High strength and corrosion resistance for structural and functional components; excellent thermal and electrical conductivity for electronics and sensors |
| Aerospace & Aviation | Avionics enclosures, actuator brackets, heat exchangers | Dimensional stability and reliability under harsh conditions; lightweight yet strong for load-bearing assemblies |
| Consumer Electronics | Connectors, heatsinks, terminal blocks | Superior electrical and thermal conductivity; precise, intricate geometries enable compact designs |
| Industrial & Machinery | Pump housings, gears, valve bodies, sensor enclosures | High wear resistance, corrosion protection, and durability for heavy-duty applications; supports integrated designs |
| Electrical & Power | Switchgear components, busbars, contacts | Outstanding conductivity and precise tolerances ensure reliable performance in high-voltage or high-current systems |
| Plumbing & Fluid Systems | Fittings, valves, couplings | Excellent corrosion resistance in water, chemicals, and harsh environments; dimensional accuracy ensures leak-free assembly |
| Telecommunications & Networking | Connector shells, shielding enclosures | High conductivity, EMI shielding, and robust mechanical strength for sensitive electronic components |
| Marine & Offshore | Propeller components, valve bodies, connectors | Corrosion-resistant in seawater and harsh climates; suitable for structural and functional marine parts |
Ready to Start Your Brass/Copper Die Casting Parts?
Our experienced engineers are here to guide through brass alloy selection, mold design, and production optimization. Discover how advanced brass die casting technologies can deliver high-quality, durable, and cost-efficient components for the next brass casting project
- yoyo@iec-mould.com
- 86 13712993487
- 86 13712993487
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