High Pressure Die Casting: Pressure die casting is a repetitive process casting identical parts by injecting Aluminum into metal moulds at pressures in the order of 1000psi. Complex machinery and expensive tooling is required for this process.

Advantages

Production rates may be in the order of 200/ Hr

Thin wall thickness at 1 - 2.5mm

The best surface finish is produced by this method

Very fine grain structure is obtainedThe castings have high strength in the as-cast condition

Good linear tolerances and repeatable properties are obtained

Limitations

Size of castings limited by the machine

Sound, thick sections are difficult to cast

Core configuration may be complex to enable disassembly

Porosity may become a concern

High start up costs require long production runs to reduce the overall cost

Castings cannot be heat treated casting weight range 0.01 Kg - 25 Kg

Approximate economical quantity range > 10,000 per annum.