Die Casting Resources

Rheocast Company is a premier manufacturer of high pressure die castings with a complete line of customer care services. It is our goal to deliver ready-to-install components to our customers. Here you will find answers for many of your questions about die casting. Many of the topics contain links to corresponding pages within our site to provide you with detailed information regarding Rheocast high pressure die casting services. If you have additional questions about our processes, capabilities or services, please feel free to connect with us! We look forward to helping you find the right die casting solution for your components.


What is die casting?
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Die casting is a versatile manufacturing process in which a die casting machine using considerable pressure injects molten metal into a steel mold or die to form products.

What capabilities can Rheocast provide?
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We manufacture brass die castings and aluminum die castings supported by value engineering, tooling design and construction, ISO9001 quality management systems, CNC machining services, and assembly services.

Who are Rheocast customers?
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Rheocast supplies high pressure die castings to OEM (original equipment manufacturer) customers serving a wide variety of industrial, commercial, transportation, agricultural and construction industries.

Does Rheocast provide custom work?
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All our die casting products are custom made to the specifications of our customers.

What quality certifications does Rheocast hold?
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Rheocast is proud to be an ISO 9001:2015 registered company

What type of materials does Rheocast work with?
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We routinely process one Aluminum die casting alloy and five Brass die casting alloys.

What information is needed for an effective RFQ?
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To develop an accurate quotation for your part we need the following information:

  1. A sample part, or a drawing of your part or a 3D model of your part,
  2. The weight of your part,
  3. Which alloy you plan to use,
  4. Your EAU (estimated annual usage), and,
  5. A description of your secondary processing requirements such as machining or finishing
What are the size limits of Rheocast die castings?
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Depending on the shape of the part we can produce castings weighing as little as an ounce to as much as 8 pounds

What type of tolerances can be met?
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The standard tolerance for brass die casting is ±0.010″ and the standard tolerance for aluminum die casting is ±0.005″; higher levels of tolerance are possible for areas of critical requirements and these can be achieved by special arrangements and planning in the mold design stage.

What are the thinnest walls that can be requested for a die cast component?
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The minimum wall thickness for Brass is 0.055″ and for Aluminum it is 0.045″

What secondary processing operations are available?
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Approximately 80% of our castings receive secondary operations ranging from simple cleaning to complex machining and coating finishes. In-House we conduct vibratory de-burring and grit-blast finishing. A broad selection of secondary processing operations is available through our network of approved subcontract suppliers.

Does Rheocast make prototypes?
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Rheocast has the capability to help you finalize your product design using actual die cast parts by constructing single-cavity prototype tools for very attractive prices. We do not, however, offer rapid prototyping processes to make single, test-pieces.

What type of quality assurance does Rheocast provide?
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Our quality management systems are registered to the ISO9001:2015 standards and we maintain a fully equipped quality lab including CMM (coordinate measuring machine), optical comparator, full complement of variable data instruments and hard gages.

What type of inventory management does Rheocast provide?
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Because each of our customers have a preferred method for managing inventory we are capable of delivering many options such as JIT (just in time), KANBAN, Carry-In-Stock and custom plans. We are prepared to tailor an inventory plan to maximize your preferred management strategy.

What areas does Rheocast service?
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Based near Milwaukee, Wisconsin, we service original equipment manufacturers nationwide.

How do I contact you?
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N114 W19250 Clinton Drive
Germantown, WI
Phone: 262-251-4942
Fax: 262-251-2102