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Your Reliable High Pressure Die Casting Supplier in China.
Solving Your Manufacturing Challenges with HPDC
IEC Mould high pressure die castings are produced using advanced cold chamber machines and high-grade aluminum and zinc alloys. Our process ensures precise, complex parts with excellent surface finish and high repeatability for automotive, electronics, and industrial applications.
What is High Pressure Die Casting?
High Pressure Die Casting (HPDC) is a precision metal casting process where molten metal is injected into a steel mold at high pressure (1,000 to 1,500 bar). The process is ideal for producing complex, lightweight, and highly detailed components. HPDC is widely used in industries like automotive, aerospace, electronics, and industrial manufacturing for parts that require tight tolerances, superior surface finish, and high production volumes.
Why Choose HPDC?
- Fast Production Cycles – HPDC offers rapid cycle times and is highly efficient for large batch production.
- Dimensional Precision – The process achieves tight tolerances (up to ±0.05mm) and is ideal for intricate parts.
- Smooth Surface Finish – Parts come out of the mold with minimal post-processing required.
- Complex Geometries – HPDC can handle thin-walled and complex shapes, making it versatile for various applications.
How High Pressure Die Casting Works?
The HPDC process involves multiple steps that work together to create highly precise metal parts.
Step 1: Preparation
The steel mold is prepped with a release agent to prevent sticking. The molds are designed for durability and precise control of temperature and cooling rates.
Step 3: Cooling and Solidification
Once the molten metal fills the cavity, it cools and solidifies rapidly. The speed of cooling is controlled to prevent defects like shrinkage or porosity, resulting in high-quality finished parts.
Step 2: Molten Metal Injection
Molten metal, typically aluminum, zinc, or magnesium alloys, is injected into the mold cavity under high pressure. The pressure ensures that the metal fills even the most intricate details of the mold.
Step 4: Ejection
The mold is opened after cooling, and the part is ejected using ejector pins. Secondary operations such as trimming, machining, or surface finishing may be required depending on part specifications.
Key Advantages of High Pressure Die Casting
Precision and Customization
Tight Dimensional Tolerances: HPDC allows for ±0.05 mm accuracy, ensuring that parts meet stringent specifications with minimal variation.
Complex Part Geometries: Ideal for producing intricate shapes and thin-walled designs that would be difficult or costly with other manufacturing methods.
Fast Prototyping & Low Cycle Time: The ability to produce parts rapidly makes HPDC an excellent choice for fast-tracking product development cycles and achieving quick market entry.
Compatibility with Multiple Alloys: HPDC works with a variety of alloys like A380, ADC12, AZ91D, etc., giving engineers flexibility in material selection based on specific part requirements.
Quality Assurance and Control
High-Quality Finish: HPDC parts require minimal post-processing due to their smooth surface finish. This minimizes defects like scratches and dimensional variations.
Process Control: Tight process control ensures parts are produced with high precision. The use of X-ray inspection, CMM measurements, and ultrasonic testing guarantees quality consistency across production runs.
Porosity Prevention: By controlling injection speed, mold temperature, and pressure, HPDC minimizes internal defects like gas porosity and shrinkage that can affect part strength.
Cost Efficiency and Reliability
Cost-Effective for High Volumes: HPDC is ideal for large-scale production due to its short cycle times and material efficiency, making it a cost-effective option for high-volume runs.
Material Sourcing & Alternatives: HPDC works with multiple alloys like aluminum, magnesium, and zinc, giving procurement teams options for material selection based on cost, performance, and availability.
Supply Chain Reliability: Partnering with an experienced supplier ensures that high-quality parts are delivered on time, with the ability to scale production based on changing demand.
Applications of High Pressure Die Casting
High Pressure Die Casting is used across various industries, thanks to its ability to produce lightweight, strong, and complex components.
Automotive Industry:
HPDC is used extensively in automotive manufacturing, producing components like: Engine blocks, Transmission housings, Brackets, Suspension parts.
These components must be lightweight, highly durable, and capable of withstanding harsh conditions, making HPDC an ideal choice.
Aerospace Industry:
In aerospace, HPDC is ideal for producing components such as: Airframe parts, Aircraft structural components, Landing gear housings, Engine parts.
HPDC enables aerospace engineers to create lightweight, high-strength parts with complex geometries that meet stringent performance requirements.
Electronics Industry:
For the electronics industry, HPDC is used to produce: Smartphone casings, Laptop housings, TV brackets and frames, Connectors and enclosures.
The smooth surface finishes and tight tolerances make HPDC ideal for parts used in consumer electronics.
Industrial Equipment:
HPDC is also employed in manufacturing parts for industrial machinery such as: Valve bodies, Pumps, Gearboxes, Electrical enclosures.
These parts require precision and strength, making HPDC the go-to process for industrial applications.
Common Technical Specifications
Injection Pressure: HPDC uses high injection pressures between 1,000 and 1,500 bar to ensure rapid and complete filling of the mold.
Cycle Time: Cycle times can range from 30 seconds to several minutes depending on the size and complexity of the part. This allows for high-volume production with consistent results.
Alloy Selection: Common alloys used include A380, ADC12, AZ91D, Zamak and AM60B. Each alloy offers unique strength, corrosion resistance, and performance properties tailored to different applications.
Wall Thickness: HPDC is ideal for thin-walled parts, with wall thicknesses as low as 0.5 mm.
Tolerances: HPDC achieves tight tolerances (±0.05 mm to ±0.1 mm), making it perfect for applications requiring high precision.
Common Challenges and Solutions
Mold Wear: Due to the high pressures used in HPDC, mold wear is a common challenge. Regular maintenance and tooling optimization can extend mold life and reduce downtime.
Defects & Porosity: Porosity and shrinkage can occur if cooling rates or injection pressures are not properly controlled. Implementing advanced process controls and non-destructive testing methods, like X-ray, ensures that these defects are minimized.
Tooling Costs: HPDC tooling can be expensive due to the high precision required for the molds. However, this cost is offset by the low per-part cost when producing high volumes.
High Pressure Die Casting Frequently Questions & Answers
What materials are best suited for High Pressure Die Casting?
HPDC is most commonly used with aluminum (e.g., A380, ADC12), zinc (Zamak 3, Zamak 5), and magnesium (AZ91D, AM60B) alloys. These metals have the right melting points and fluidity for high-pressure injection, allowing for thin-walled, complex geometries.
What are the typical tolerances achievable with HPDC?
HPDC can achieve tight dimensional tolerances, typically ±0.05–0.1 mm, depending on the size and complexity of the part. Proper tooling design, process control, and mold maintenance are key to maintaining these tolerances.
How does HPDC compare to Low Pressure or Gravity Die Casting?
HPDC is best for high-volume production of thin-walled parts with excellent surface finish and tight tolerances.
LPDC is used for larger parts requiring low porosity and strong mechanical properties, often in automotive structural parts.
Gravity Die Casting is more cost-effective for medium-volume runs with moderate complexity.
What is the maximum part size for High Pressure Die Casting?
HPDC is ideal for small to medium-sized parts. Typical part weights range from a few grams up to ~20 kg, though the maximum size depends on machine clamping force and mold design.
Are HPDC parts heat-treatable?
Most aluminum HPDC alloys are not heat-treatable because of trapped gas porosity. However, certain specialized alloys and vacuum die casting processes can produce parts suitable for heat treatment. Consult our engineers for material recommendations.
What surface finishes are available for HPDC components?
HPDC parts come with a smooth, high-quality as-cast finish. Additional surface finishes can be applied:
Powder coating or painting
Anodizing (for aluminum)
Plating (zinc, chrome, nickel)
Shot blasting or polishing
What quality assurance methods are used for HPDC parts?
We follow ISO 9001 and IATF 16949 standards and use:
CMM (Coordinate Measuring Machine) inspections, X-ray and ultrasonic testing for porosity, SPC (Statistical Process Control) during production, 100% traceability for every batch
