High-pressure die casting is the preferred manufacturing process for low-cost, high-specification components with complex shapes. These include aluminum and brass components in many industries such as plumbing, hardware, automotive and agriculture. High-pressure die casting excels in producing intricate shapes with repeatability, durability and dependable quality.

Brass Die Castings are recommended for:

• Rugged durability
• Electrical conductivity
• Beauty

Aluminum Die Castings are preferred for:

• Performance
• Good looks
• Low Cost

With Rheocast’s capabilities, we can produce the components you need:

• Less than 1 ounce or up to 10lbs
• Short and long runs
• Net or near-net results
• Thin or thick walls
• Excellent mechanical and electrical properties
• Cost-effective alternative to other casting and machining processes

What is High-Pressure Die Casting?

High-pressure die casting is a versatile manufacturing process in which a die casting machine uses considerable pressure to inject molten metal into a steel mold or die cavity to form products. These molds or dies can produce complex shapes with exceptional accuracy and repeatability. High-pressure die castings are extremely durable, have excellent electrical and mechanical properties, and are cost effective. Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry.

Rheocast specializes in cold chamber aluminum and brass die casting. In cold chamber die casting, a precise amount of molten metal is fed into a ‘cold chamber’ where a hydraulic plunger forces the metal into a sealed die at high pressures.

Advantages of High-Pressure Die Casting

Die castings are made using nonferrous metals such as aluminum, zinc, brass, copper or magnesium. Compared to other manufacturing processes, high-pressure die casting is an efficient, economical process that:

Produces stronger, lighter weight components that require less machining than fabricated parts
Creates complex and intricate shapes in a single homogenous piece, eliminating assemblies and welding
Offers a broader range of shapes than many other metal manufacturing techniques
Achieves closer tolerances than other metalworking processes
Can create components designed to complement the look of a surrounding part

Finishes and Textures

Rheocast can produce die castings with smooth or textured surfaces, which are easily plated or finished with minimum surface preparation. We can add finishing services like polishing and coating options ranging from plain brass or aluminum polishing to heavy-duty industrial service.

For more die casting information, see our Die Casting Resources page.