High-volume, precision die casting in aluminum, zinc, and magnesium alloys. From prototype to production, we deliver complex, near-net-shape components with exceptional surface finish and dimensional accuracy.
MetalCore's die casting division operates one of the most modern facilities in the region, equipped with hot and cold chamber machines ranging from 100-ton to 2,500-ton capacities.
Die casting is a manufacturing process where molten metal is injected into a mold cavity under high pressure. This method produces parts with excellent surface finish, tight tolerances, and high dimensional consistency — making it ideal for high-volume production runs.
Our experienced metallurgists and tooling engineers work closely with your team during the design phase to optimize part geometry for manufacturability, ensuring the most cost-effective production while maintaining the highest quality standards.
We specialize in both hot chamber die casting (primarily for zinc and magnesium) and cold chamber die casting (for aluminum alloys). Each process is selected based on your material requirements, part geometry, and production volume.
With integrated die design, CNC machining, and finishing capabilities, MetalCore offers complete turnkey solutions — from initial concept through final delivery. Our in-house quality lab performs CMM inspection, X-ray testing, and mechanical property verification on every production lot.
Our streamlined die casting process ensures quality, consistency, and on-time delivery at every stage.
Our engineering team reviews your part design for die castability. We perform detailed Design for Manufacturing (DFM) analysis, recommending optimal wall thicknesses, draft angles, rib placements, and gate locations to minimize defects and reduce cost.
Our in-house tooling team designs and manufactures custom aluminum or hardened steel dies. We use 3D simulation software to predict filling patterns, cooling, and potential defects before a single die is cut — saving time and cost.
Once the die is complete, we run initial trial shots and perform comprehensive validation — including dimensional inspection, mechanical testing, and X-ray inspection. You receive sample parts for approval before full production begins.
High-volume production with rigorous in-process quality checks. Every cavity is monitored for temperature, pressure, and cycle time. Statistical Process Control (SPC) ensures consistent quality across every production lot.
Parts undergo trimming, deburring, CNC machining for tight-tolerance features, and surface treatments as specified — including anodizing, powder coating, painting, plating, or bead blasting.
Parts are carefully packaged to prevent damage during transit. We provide full documentation including material certificates, inspection reports, and first article inspection (FAI) reports. Global shipping arranged to your facility or distribution center.
We work with a wide range of die casting alloys, each selected for specific mechanical properties and application requirements.
The most widely used die casting material. Aluminum offers an excellent strength-to-weight ratio, good corrosion resistance, thermal conductivity, and natural finish. Ideal for automotive, electronics, and appliance housings.
Zinc die casting provides exceptional dimensional accuracy, superior surface finish, and excellent mechanical strength. Ideal for precision components, hardware, and parts requiring secondary operations like threading or plating.
Magnesium is the lightest structural metal, offering the best strength-to-weight ratio. It provides excellent damping characteristics, electromagnetic shielding, and machinability. Popular in aerospace, automotive, and consumer electronics.
Die casting delivers unmatched efficiency and precision for high-volume metal part production.
Cycle times as fast as 15–30 seconds per part. Mass production runs of thousands of parts per day are achievable with our high-speed automated lines.
Hold tolerances as tight as ±0.05mm without additional machining. Excellent dimensional repeatability part after part, reducing post-processing costs.
Naturally smooth surfaces (Ra 1–3 μm) suitable for aesthetic applications. Can be polished, plated, anodized, or powder coated to exact specifications.
While die tooling has upfront cost, the per-part cost drops dramatically at volume. Ideal for runs of 1,000+ to millions of parts annually.
High strength, impact resistance, and fatigue life. Thin-wall capabilities (as thin as 0.5mm) enable lightweight designs without sacrificing strength.
Produce intricate shapes with internal features, integrated bosses, ribs, and threads. Combine multiple components into a single casting for assembly savings.
Our die casting solutions power critical components across multiple industries.
Engine blocks, transmission housings, brake calipers, steering components, and body panels.
Housing assemblies, structural brackets, engine components, and satellite parts.
Heat sinks, enclosures, chassis, connector housings, and thermal management parts.
Device housings, surgical instrument components, and diagnostic equipment parts.
Hardware, fasteners, connectors, pump housings, and architectural metal components.
EV battery housings, solar panel mounts, generator components, and turbine parts.
Appliance housings, power tools, sporting goods, and decorative hardware.
Pump housings, valve bodies, gear housings, and machinery components.
Understand where die casting shines compared to other metal forming methods.
| Feature | CNC Machining | Die Casting (MetalCore) |
|---|---|---|
| Best For Volume | 1 – 1,000 parts | 1,000 – millions of parts |
| Per-Part Cost at Scale | High | Very Low |
| Tolerance | ±0.01mm | ±0.05mm |
| Surface Finish | Machined lines | Smooth (Ra 1–3 μm) |
| Complex Geometry | Moderate | Excellent |
| Production Speed | Minutes per part | Seconds per part |
| Upfront Tooling Cost | Low (programming only) | Moderate (die tooling) |
| Material Waste | High (subtractive) | Low (near-net-shape) |
See how our die casting solutions delivered measurable results for our clients.
A leading EV manufacturer needed a complex motor housing with integrated cooling channels and precise bearing journals. We designed a 1,500-ton cold chamber aluminum die casting solution using A360 alloy, achieving a 40% weight reduction over their previous machined design.
Common questions about our die casting services answered.
While die casting is most cost-effective for runs of 1,000+ parts, we can accommodate smaller production runs depending on part complexity and existing tooling. For prototyping, we recommend 50–200 parts using a softer steel trial die before investing in hardened production dies.
Standard production dies typically take 6–10 weeks from design approval to first article. Complex multi-cavity dies with hot runner systems may take 12–16 weeks. We offer expedited tooling programs for urgent projects at a premium. Trial (soft steel) dies can be produced in 4–6 weeks.
Hot chamber die casting has the injection mechanism submerged in the molten metal — ideal for zinc and magnesium with lower melting points. Cold chamber die casting requires molten metal to be ladled into a separate shot sleeve — used for aluminum alloys with higher melting temperatures. We operate both types and recommend the best process for your application.
Absolutely. We offer complete turnkey services including CNC machining of critical features, tapping, deburring, polishing, bead blasting, anodizing, powder coating, painting, and plating. Our in-house secondary operations eliminate the need for multiple suppliers and reduce lead times.
MetalCore is ISO 9001:2015 certified and IATF 16949 certified for automotive manufacturing. Our die casting division meets PPAP requirements and can provide full traceability documentation including material certificates, inspection reports, and CMM data for every production lot.
From initial concept to first production parts, typical lead time is 12–20 weeks depending on part complexity, die size, and production volume. This includes DFM review (1 week), die design & fabrication (6–10 weeks), trial runs & validation (2 weeks), and tooling adjustments (1–3 weeks). We work closely with you on scheduling to meet your target dates.
Send us your drawings, specifications, or part requirements and receive a detailed quote within 24 hours.