X-Ray Radiography
NDT inspection for internal porosity, inclusions, and structural integrity.
Die Casting (Aluminum / Zinc / Magnesium)
High-pressure and cold-chamber die casting services for complex, high-volume components. Engineered for structural integrity, tight tolerances, and superior surface finish.
Process Overview
MetalCore's die casting facility specializes in high-volume production of precision metal components using hot-chamber and cold-chamber processes. Our engineering team collaborates from the initial CAD review through part optimization, tooling design, and full-scale production, ensuring manufacturability, cost-efficiency, and strict dimensional control.
With presses ranging from 150 to 2,500 tons and automated shot systems, we deliver consistent part quality for aerospace, automotive, medical, and industrial applications. All tooling is designed in-house using advanced simulation software to predict flow, cooling, and potential porosity before first article production.
Material Capabilities
Aluminum Alloys Al
Lightweight, excellent thermal conductivity, and high strength-to-weight ratio. Ideal for heat sinks, housings, and structural brackets.
- A380, A360, A356, AC4C
- Hot & Cold chamber processes
- Applications: Automotive, Electronics, HVAC
Zinc Alloys Zn
Superior fluidity, excellent surface finish, and natural zinc plating capability. Supports thin-wall geometries and high detail resolution.
- ZAMAK 2, 3, 5, 7; ZA-8, ZA-12
- Hot chamber process
- Applications: Consumer goods, fasteners, electrical housings
Magnesium Alloys Mg
Lightest structural casting metal. High specific strength, excellent damping capacity, and machinability.
- AZ91D, AZ31B, AM60B
- Gravity & Low-pressure processes
- Applications: Aerospace, portable electronics, robotics
Technical Specifications
| Press Tonnage | 150T – 2,500T |
|---|---|
| Shot Size | 0.5 oz – 50 lbs per shot |
| Part Size Range | 0.25" to 36" maximum dimension |
| Standard Tolerances | ±0.005" first 0.5", then ±0.001" per additional inch (per C2C/C2M) |
| Thin-Wall Capability | Zinc: 0.030" | Aluminum: 0.040" | Magnesium: 0.045" |
| Surface Finish | As-cast, bead blasted, polished, powder coated, anodized, plated |
| Annual Capacity | 5M+ parts per year |
Quality Control & Testing
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CMM Inspection
Multi-axis coordinate measuring for critical GD&T verification.
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Pressure Testing
Leak testing for fluid and pneumatic applications per customer specs.
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Material Certifications
Mill certs, SPC reports, and full traceability documentation.
Frequently Asked Questions
Standard tooling lead times range from 8 to 14 weeks depending on complexity, cavity count, and steel specifications. Expedited timelines are available for urgent programs.
Yes. We offer soft-tooling prototypes in 2-4 weeks for functional testing and design validation. These use aluminum or beryllium-copper molds to accelerate your development cycle.
Post-casting services include CNC machining, trimming, deburring, tapping, thermal treatment (T5/T6), shot peening, and various surface finishes including anodizing and powder coating.
Yes. We offer scheduled preventive maintenance, hot runner repairs, cavity refurbishment, and mold storage services to maximize tool life and maintain consistent part quality.