Die Casting

Die-casting is a metal-forming process. Molten metal is poured into a mold to create components with high precision, intricate detail, and fits that are perfect for functional use. Die-cast components are popular in automotive, aerospace, power equipment, lighting, firearms, and multiple other industries.

Die-cast components are mass-produced in various metal alloys, including aluminum, zinc, copper, brass, and bronze alloys.

Once a component has been die-cast, it can be further refined with CNC machining. Surface finishes are commonly applied through processes like shot-blasting, texturing, plating, and painting.

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Get Your Custom Die Cast Components

Our team's tool design experience and use of industry-leading software and mold flow analysis tools ensure the production of high-quality die-cast parts. We support both high-volume production and short-run batch production (soft-tooling).


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Zetwerk’s Die Casting Service

Zetwerk provides high-quality die-cast components produced using a range of materials including aluminum, zinc, copper, brass, and bronze. We also perform secondary operations on the die-cast parts such as finish machining and surface treatment.

Zetwerk Offers Industry-Leading Tool Design and Software Expertise

Our team’s tool design experience and use of industry-leading software and mold flow analysis tools ensure the production of high-quality die-cast parts.

We support both high-volume production and short-run batch production (soft-tooling).

Get a Quote

 

investment casted components

Zetwerk is ISO 9001:2015 and AS9100D certified. Our die-casting plants are IATF 16949:2016 certified.



Die Casting Processes and Machines

All of the casting processes offer varied advantages. We help our customers select the right process based on a variety of factors. Examples are annual volume, part size, weight, geometry, and surface finish requirements.

Zetwerk employs several of the most common die casting processes including High Pressure Die Casting (HPDC), Low-Pressure Die Casting (LPDC) and Gravity Die Casting (GDC). Each of these processes can also support the semi-permanent casting process. This casting process uses one or more sand cores to form internal passages within the production die-cast component.

Zetwerk can provide die-cast components using hot chamber and cold chamber production die casting machines. Machine tonnage is selected based on factors such as part size and cavitation. Zetwerk offers a wide range of material selections, including aluminum alloys, zinc alloys, brass, copper, and magnesium.

dies cast components



Secondary Operations and Surface Finishes for Die-Cast Components

Secondary Operations & Finishing Processes

Once production components are die-cast, they are subjected to one or more finishing processes to remove the gates, overflows, and any flash. Finishing is also used to smooth out the parting lines on the component.

Some of the secondary operations and finishing processes offered:

  • Drilling, tapping and reaming to ensure specific features, areas, and dimensions of the castings meet the required tolerances.
  • Precision CNC machining to meet design criteria and dimensional tolerances.
  • Vibration, tumbling, and thermal deburring to remove burrs and other imperfections from die-cast parts.

… and many more

Surface Finishes Offered

Examples of the surface finish options offered:

  • Conversion Coating to remove any surface impurities or contaminants.
  • Shot Blasting to create textured surfaces
  • Surface Coating to improve surface finish
  • Cosmetic and Decorative Surface Finishes to protect against corrosion and enhance wear resistance and durability.
  • Polishing to remove stains, oxide remnants, etc. from aluminum surfaces.
  • Black, Clear and Other Types of Anodizing
  • Painting with a range of options and color choices
  • Plating for high-quality cosmetic surface finishes

… and many more



Additional Services

Zetwerk provides additional services like testing, heat treatment, and assembly of cast components.

Examples of additional services provided:

  • Salt Spray Testing to confirm corrosion resistance specifications.
  • Hydrostatic and Pneumatic Pressure Tests to check for leakage and the possibility of bursts.
  • Assembly Services can be provided when required. We can also procure additional hardware locally to complete assembly.

Die Casting Certifications

Your parts will be manufactured in the plants with IATF 16949:2016 automotive quality certification (in October 2016, IATF 16949:2016 replaced ISO/TS 16949:2009).

Zetwerk has global quality expertise in FMEA, APQP, PPAP, SPC, and MSA and is AS 9100D & ISO 9001:2015 certified.



THE ZETWERK MANUFACTURING DIFFERENCE

Zetwerk provides a full suite of services focused on reducing turnaround time and improving efficiency and value. Zetwerk delivers projects that are more cost effective and are brought to market sooner.

PROJECT MANAGEMENT

Zetwerk offers project management throughout the manufacturing process. After you create a PO, our team will guide you through each step. They will keep you up-to-date with the information you need to monitor production and share project information with internal stakeholders.

Die Casting Tooling Design

Tooling design is an optimization step that can improve speed when manufacturing die casted components. The tooling’s design considers manufacturing tolerances and typical wear from usage.

Optimizing tooling is an often overlooked step when processing die casting requirements. Adding this step into the manufacturing process saves critical time during process development and ensures the tooling will meet your project’s needs.

FAIR APPROVAL

A first-article inspection report (FAIR) is a part of any robust product development program. It is also critical to conduct detailed inspections to avoid out-of-tolerance components and rework for extruded components. Zetwerk’s process incorporates this essential step, giving you complete confidence in the parts you receive.

MANAGED INVENTORY FOR JIT

Global events of the early 2020s have demonstrated the importance of inventory management and supply chain resiliency. The traditional approach to JIT strains your ability to react to market or order fluctuations. Having a globally connected supply partner is an effective way to build resiliency and multi-source supply.



GET A QUOTE FOR DIE-CASTING

Zetwerk is your one-stop solution for complete end-to-end contract manufacturing and distribution. We provide:

  • Unlimited manufacturing capacity decreases risk and improves your ability to respond to demand fluctuations
  • Global raw material sourcing to protect cost and supplier resiliency
  • Secondary processing, including anodizing, powder coating, and CNC machining
  • Assembly, packaging, and distribution
  • Quality control – AS 9100D & ISO 9001:2015 certified
  • Vendor managed inventory to optimize material availability
  • Supply chain management for efficient raw material conversion
  • Project management for a hands-free experience, with weekly updates for project and timing accountability

Experience the difference Zetwerk makes in your manufacturing process. Request a quote today for die-casting or any other manufactured component.

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