The best part about the metal fabrication and manufacturing industry is that hundreds of resources and alternatives are available for each requirement. In addition, there are methods available for specific components and shapes, from die casting, injection molding, sand casting, extrusion, etc.

While this makes things better for the quality, sometimes you could get confused between them. One such comparison is between cast aluminum and die-cast when determining the proper method for manufacturing. Let us understand the difference between cast aluminum and die-cast in detail.


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Difference Between Cast Aluminium & Die Cast

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While cast aluminum involves aluminum components designed with a casting process done with molten aluminum, die cast is a casting method involving high-pressure die casting with raw materials. The significant difference between the two is the material for casting the products.


To cast aluminum in different components, die casting is done by melting it and pouring it into the mold. The metal then solidifies and gets the desired shape. This is what cast aluminum is all about. At the same time, the process itself is called die casting.


While the process is quite similar for both cast aluminum and die-cast, the methods of both are different. Die-cast includes methods like sand casting, gravity casting, low-pressure casting, and other casting processes. All these casting methods involve various molds and metals like copper, aluminum, iron, and magnesium. In contrast, cast aluminum is nothing but a casting method made with only aluminum metal to cast aluminum products.

However, the cast aluminum is done with different heat treatments. T6 is the most common heat treatment. On the other hand, T6 is not suitable for die casting due to a large amount of gas distributed inside the chamber. 

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  • With a rigid body and structure, cast aluminum is better in strength and lightweight to create thousands of components.
  • From small devices to big trucks, it provides heat resistance and strength.
  • Famous for home appliances, patio furniture, and cookware.
  • Aluminum being affordable makes the entire process cost-effective and long-lasting, with many features that aluminum brings.
  • Great for electronics due to performing in fluctuating temperatures and thermal conductivity.


  • Die-cast is ideal for mass production and complex shape designs.
  • Die casting creates parts and components that are more durable, aesthetically appealing, and dimensionally stable than other methods.
  • It can be done with thinner walls than other casting methods, and the produced parts are much stronger than other methods.
  • You can produce thousands of identical parts within specified tolerances before additional procedures and tooling.
  • Die casting is an effective option with various molds and materials compatible with the process.


Each process comes with its advantages and drawbacks. However, die casting is the most preferred due to its ability for mass production and the various options available. On the other hand, the aluminum cast is ideal for aluminum parts and components.

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