WHAT IS PRESSURE DIE CASTING?
Pressure die casting is a manufacturing process where molten aluminum is injected into a steel mold (die) under high pressure. This produces components with excellent surface finish, tight tolerances, and complex geometries that would be difficult to achieve with other methods.
At PSA Engineering, we specialize in high-pressure die casting (HPDC) for aluminum alloys, delivering parts that meet demanding specifications for electrical, lighting, and electronics applications.
High Production Speed
Fast cycle times for efficient high-volume manufacturing
Excellent Surface Finish
Smooth surfaces ready for painting or powder coating
Complex Geometries
Thin walls, intricate details, and integrated features
Cost Effective
Lower per-part cost at medium to high volumes
DIE CASTING EQUIPMENT
Our fleet of 4 pressure die casting machines handles a wide range of part sizes
PDC MACHINE 1
Cold chamber die casting for small to medium components
PDC MACHINE 2
Versatile machine for a variety of part sizes
PDC MACHINE 3
Medium capacity for larger components
PDC MACHINE 4
High capacity for larger housings and enclosures
DIE CASTING PROCESS
From raw material to finished component in a controlled, repeatable process
MELTING
Aluminum alloy ingots are melted in a furnace at temperatures around 660-700°C. The molten metal is maintained at optimal temperature for casting.
INJECTION
Molten aluminum is ladled into the shot chamber and injected into the die cavity at high pressure (typically 700-2000 bar) using a hydraulic plunger.
SOLIDIFICATION
The metal rapidly solidifies in the die under pressure. Cooling channels in the die help control solidification for optimal metallurgical properties.
EJECTION
The die opens and ejector pins push the casting out. The cycle time is typically 30-90 seconds depending on part size and complexity.
TRIMMING
Excess material (flash, runners, overflows) is removed. Parts may go through deburring to remove any sharp edges.
FINISHING
Secondary operations like CNC machining, drilling, tapping, and surface finishing (powder coating, painting) are performed as required.
MATERIALS WE CAST
We work with various aluminum alloys suited for different applications
ADC12
Most common die casting alloy with excellent castability and good mechanical properties. Ideal for general-purpose applications.
LM6
Excellent corrosion resistance and good fluidity. Often used for marine and outdoor applications requiring weatherproofing.
LM24
Good strength and hardness with excellent machinability. Suitable for components requiring secondary machining operations.
APPLICATIONS
Components we produce through pressure die casting
ELECTRICAL FITTINGS
Precision enclosures and housings for electrical applications with excellent dimensional accuracy.
LIGHTING COMPONENTS
Heat sinks and housings with optimized thermal performance for LED and conventional lighting.
ELECTRONICS HOUSINGS
EMI shielded enclosures and precision housings for electronic equipment.
CAPABILITIES & TOLERANCES
Technical specifications for our die casting services
| Parameter | Specification | Notes |
|---|---|---|
| Part Weight Range | 50 grams to 5 kg | Depending on geometry |
| Dimensional Tolerance | ±0.1mm to ±0.3mm | ISO 8062 CT6-CT8 |
| Minimum Wall Thickness | 1.5mm | 2mm recommended for best results |
| Surface Finish | Ra 1.6 - 3.2 μm | As-cast finish |
| Draft Angle | 1° - 3° | For easy ejection |
| Materials | ADC12, LM6, LM24 | Other alloys on request |
| Production Volume | 500 to 100,000+ pieces | Economical at higher volumes |
| Secondary Operations | CNC, VMC, Powder Coating | All in-house |
QUALITY CONTROL
Ensuring every casting meets specifications
DIMENSIONAL CHECK
All critical dimensions verified using calibrated measuring instruments
VISUAL INSPECTION
100% visual inspection for surface defects, porosity, and finish quality
WEIGHT MONITORING
Part weight tracking to ensure consistency across production runs
DOCUMENTATION
Complete traceability with inspection reports and material certificates
READY TO DISCUSS YOUR PROJECT?
Share your drawings or samples and get a quote for your die casting requirements. Our team will review your specifications and provide the best solution.