Achieve complex geometries and tight tolerances with our in-house tooling capabilities

<p>Achieve complex geometries and tight tolerances with our advanced in-house tooling capabilities.</p>

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Die casting tooling

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Dynacast offers advanced die casting tools, backed by rapid on-site support and a dedicated tooling centre.

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Rapid support

Our tools start with design for manufacturing, involving detailed customer discussions to identify any part shortcomings before constructing the tool to improve the final part and enhance tool quality.

Design optimisation

In-house tooling allows for greater oversight and precision in the toolmaking process, resulting in higher quality tooling and ultimately, higher quality die castings.

Metal part in the engineering prototyping lab

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Improved quality control

We standardise our dies and die casting equipment globally and coordinate our tooling resources worldwide. No matter where you manufacture, we provide comprehensive support from start to finish. 

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Global die support

The power of in-house tooling

Our die casting tooling solutions are designed to be adaptable and customised to meet the specific requirements of each project.

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Shrinkage porosity results from the casting metal shrinking as it solidifies, leaving small pores in the part. Multi-Slide tooling delivers intricate, precise castings in a single shot, eliminating secondary operations and minimising part variation. 

Multi-Slide die casting tooling

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Conventional die casting utilises two-part moulds for efficient, high-volume production and reduced die wear.

Conventional die casting tooling 

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DFM expertise optimises product design for efficient and cost-effective manufacturing.

Design for manufacturing

Dynacast operates an in-house machine-building centre to develop specialised die casting equipment.

Machine building

Tooling solutions for every project

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<p>One of the factors that continues to distinguish Dynacast from other die casting companies is our unique four-slide (Multi-Slide) casting machines. We have many different types of proprietary machines that enable faster cycle times and tighter tolerances, giving our customers a variety of options for their die casting requirements.</p><h2>Higher quality requirements: A2 Thruster</h2><p>Created in 2008, our A2 machine can handle <strong>components from 3.5 to 35 grams and 75x65 mm</strong>. It has four pneumatic movements and four hydraulic thrusters, providing a clamping force of up to six tons. The machine is a low-cost solution used for higher quality requirements. Compared with other <a href="/die-casting-technologies/machine-building" target="_self">die casting machines</a>, our A2 is capable of more cavities and a higher shot weight. A2 Thrusters have a flexible crosshead adaptor system and a fast pneumatic injection system. The clamping force is independent of the air supply because it uses hydraulic thrusters.</p><h2>Create parts with less flash: A206 SIS</h2><p>The A206 SIS machine was first created for Dynacast in 2011. Based on the A2 Thruster machine, it is a low-cost SIS machine used for higher quality requirements. Like the A2 Thruster, the A206 SIS has four pneumatic movements and four hydraulic thrusters, providing up to six tons of clamping force. The machine also requires minimal floor space.</p><p>One of the main differences between the A2 and the A206 SIS is that the A206 has an SIS hydraulic injection system. <strong>This system uses two-phase injection to avoid excessive flash and improve a part's surface quality and porosity, thereby improving part quality</strong>. Fixed process parameters provide high repeatability. A key feature of this machine is the ability to compare data from current runs with previous runs. This allows us to easily see whether parts are manufactured consistently throughout the entire process.</p><h2>Flawless surface quality &amp; reduced porosity: A210 SIS</h2><p>The A210 SIS machine was created in 2009. This machine is typically positioned between our A2 and A3 machines and has ten tons of clamping force. The A210 SIS can use all available A2 die sizes – which means it can produce components up to 100 x 100 mm. The shot weight is up to 90 grams and, like the A206 SIS, it contains an SIS injection system. The A210 SIS machine fills parts faster without excessive flash, improves surface quality and reduces part porosity. It has high CPM rates for A3 parts while accommodating more cavities for A2 parts than previous machines. Set-up time is also faster because it has a quick connector system for slides.alloy for your next project.  </p><h2>High-quality decorative metal components</h2><p>The A2 machines available to us enable us to produce parts in high volumes while ensuring the best quality. Our high-density capabilities with our <a href="/die-casting-technologies/multi-slide" target="_self">Multi-Slide SIS machines</a> make it possible to create metal components without internal voids, enabling highly decorative components to be produced at a higher yield rate.</p><p>We continually upgrade and update these machines to keep them running smoothly and ensure they incorporate the latest technology. If you are seeking a partnership to help you apply new tools and technologies, or to fully realise your design vision, let us help move your business forward; contact our team today to start the conversation.</p>

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Explore how A2 Multi-Slide die casting machines deliver speed, precision and lower tooling costs for small, complex components in production programmes.

Benefits of A2 die casting machines | Dynacast

Dynacast's A2 machines offer high-quality, efficient die casting solutions for a variety of components, thanks to their Multi-Slide design, hydraulic thrusters and SIS injection systems. 

Benefits of A2 Multi-Slide die casting machines

<p><a href="/die-casting-technologies/sub-assembly" target="_self">Injection metal assembly (IMA)</a> is a 4-step process that replaces and outperforms conventional assembly methods, including crimping, soldering, staking and welding. IMA is well suited to assembling components of different shapes, sizes and materials, including metals, ceramics, glass, fibres, paper, elastomers and plastics.</p>

Benefits of Injected Metal Assembly Video

Injection metal assembly (IMA) is a 4-step process that replaces and outperforms conventional assembly methods, including crimping, soldering, staking and welding. IMA is well suited to assembling components of different shapes, sizes and materials, including metals, ceramics, glass, fibres, paper, elastomers and plastics.

What is injected metal assembly?

<p>High-pressure die casting is a fast, repeatable process that delivers quality metal components every time—but only if your component is designed properly. Many factors contribute to a successful design for high-volume manufacturing, and our team of engineers helps thousands of customers successfully launch new projects each year.</p><h2>What is injected metal assembly?</h2><p><em>There are many different methods of joining metal and other materials, and depending on your industry, certain considerations determine the most effective assembly method. If you currently crimp, solder, stake or weld components together, injected metal assembly (IMA) could be a more efficient and reliable option.</em><br />What is injected metal assembly?</p><p>The IMA process is a type of <a href="/die-casting-technologies/sub-assembly" target="_self">Insert Moulding</a> that uses a molten zinc alloy to join similar or dissimilar components and create a single assembled part that is strong, flash-free and repeatable. With production rates of up to 1,000 parts an hour, IMA bonding ensures consistently higher-quality parts while keeping manufacturing costs low.</p><p><strong>The uneven heating and cooling of the welding process produces brittle joints that are vulnerable to stress. As a result, their fatigue strength is far lower than that of components joined by IMA.</strong></p><h3>How does IMA work?</h3><p>First, the components to be assembled are placed into the machine in a custom-designed casting tool. These custom tools can accommodate components of various shapes, sizes and materials.</p><p>Next, the tool closes and precisely aligns to hold the components in position while the molten alloy is injected into the cavity at the intersection of the components. The alloy—usually zinc for its high strength, dimensional stability and load-bearing characteristics—solidifies in a fraction of a second and produces a strong, permanent lock between the components. Finally, the tool opens and the assembled part is ejected from the die. The ejected component is flash-free, requires no secondary operations and is stronger than conventionally joined metal components.</p><p><em>When the zinc alloy is injected, it fills the cavities in the custom tool and hardens to create a permanent bond between the components.</em></p><p>In addition to their high strength and stability, <a href="/metals/zinc" target="_self">zinc alloys</a> are predictable in their flow and shrinkage characteristics, enabling our designers to calculate the final dimensions of the injected metal joint with high accuracy. This allows for exacting tight tolerances to improve the overall functionality of the part.</p><h3>What volume is required for the IMA process to be viable?</h3><p>Dynacast can run varied volumes, from as few as 5,000 pieces a year if required to 3 to 4 million parts per year with the help of automation and robotics. Production volume is largely dependent on customer requirements.</p><h3>When joining metal and a material such as plastic, how do you prevent the plastic from melting when it comes into contact with the injected molten metal?</h3><p>With IMA, we can hold the die closed for up to a full second, depending on the fragility of the plastic, and allow the heat to dissipate in the water-cooled tool. In addition to this cooling process, the low melting point of injected metal prevents thermal degradation of the parent materials.</p><h3>Can you prototype an IMA part?</h3><p>Yes. While we cannot create a complete part before production begins, Dynacast can build simple “soft tooling” and create part-specific cavity blocks to insert into the tooling for a low-production concept. Dynacast also offers a pull-ahead system, where we build the tool to a certain point and, if the produced parts are accepted by the customer, complete the tool.</p><h3>How does IMA reduce cost?</h3><p>IMA reduces cost by cutting production time and eliminating the need for secondary operations. While processes such as welding, soldering and crimping are often very labour-intensive, IMA has the potential to be fully automated. When the part is ejected, flash-free and permanently bonded, it is ready for use.</p><h3>What major markets are served by the IMA process?</h3><p>The IMA process serves virtually any industry and application. <a href="/industries/automotive" target="_self">Automotive</a>, <a href="/industries/enterprise-technology" target="_self">telecommunications</a>, <a href="/industries/consumer-electronics" target="_self">electronic components</a>, <a href="/industries/hardware" target="_self">hardware and appliances</a>, industrial controls and military industries often use parts manufactured by the IMA process.</p>

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Discover Dynacast's IMA process—a cost-effective method using molten zinc to join components, enhancing strength, reliability and reducing assembly steps.

What is injected metal assembly? | Dynacast article

Injected Metal Assembly (IMA) is a high-efficiency manufacturing process that uses a molten zinc alloy to permanently join metal components with precision, creating strong, flash-free parts with reduced production costs and enhanced reliability compared with traditional methods such as welding and soldering.

Enhance your knowledge of Dynacast tooling

A leading manufacturer of air brake systems needed a reliable partner for their zinc die casting, requiring flawless quality and consistent supply for their safety-critical components. They sought a partner who could seamlessly manage the crucial transfer of several existing tools while maintaining existing production.

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The challenge

Dynacast provided both Multi-Slide and conventional die casting at the Peterborough facility, offering flexibility while leveraging in-house tooling expertise for rapid adjustments. Throughout the transfer, Peterborough maintained proactive communication and close collaboration with the air brake manufacturer’s engineers, ensuring seamless integration, efficient support, and the consistent maintenance of standards for safety-critical components.

High-quality standards delivered

The tooling transfer was executed smoothly, ensuring no disruption to the production schedule while maintaining the high-quality standards required for the air brake manufacturer's safety-critical components.

Ensuring uninterrupted production

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<p>The average household refrigerator is opened 22 times per day. With each look inside, cold air escapes and warm air from the surrounding room circulates through. Once the doors are closed, the compressor must kick in to re-cool the air and contents inside--affecting the owner’s energy bill and environmental footprint. But what if there was a way to access everyday items, such as drinks and snacks, without affecting the rest of the internal contents?</p><p>&nbsp;</p><img asset_uid="bltd37d37ea0927e96f" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltd37d37ea0927e96f/670692c50d678426a923e75f/Picture17.png" alt="Picture17.png" height="auto"/><h2>INNOVATION THROUGH ALUMINIUM DIE CASTING</h2><p>When the design team at a leading appliance manufacturer approached Dynacast to learn about <a href="/die-casting-technologies" target="_self">die casting capabilities</a>, they were unsure where and how they could benefit from the manufacturing process. The team at Dynacast Elgin was eager to help and offered an educational seminar to design engineers, outlining technical capabilities, material offerings, and overall benefits of die casting in the appliance industry. With a new design in mind, the engineers engaged Dynacast’s design for manufacturing (DFM) to find the best solution. Aluminium was very attractive to the team due to its lightweight properties and high strength-to-weight ratio. Specifically, appliance engineers focused on decorative <a href="/metals/aluminum" target="_self">aluminium die casting</a> for a new French-door refrigerator concept. The appliance would offer a door-in-door feature to allow the consumer access to popular items without opening the entire refrigerator and wasting cold air. By allowing the interior doors to stay closed and keep warm air out, the refrigerator would offer an innovative way to reduce energy consumption.</p><p>&nbsp;</p><img asset_uid="blt871d3bf515f59c88" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/blt871d3bf515f59c88/670692c5a75c92f2970a2b62/Picture18.jpg" alt="Picture18.jpg" height="auto"/><h2>MAXIMISING “SHELF LIFE”</h2><p>The appliance company’s marketing team was interested in offering a swinging “milk shelf” to allow easy access to this common household staple. Connection of the milk shelf to the interior body of the refrigerator would be via a hinge component. In order to withstand the weight of a gallon of liquid, engineers determined that the hinge would need to be stronger and more durable than plastic. The castability of zinc, its wear resistance, and structural integrity made it the ideal material choice.</p><p>&nbsp;</p><img asset_uid="bltbcfda9c92a3fe4c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltbcfda9c92a3fe4c1/670692c5a75c9286890a2b64/Picture19.jpg" alt="Picture19.jpg" height="auto"/><p>In addition to offering functionality and stability, the shelf attachment needed to be decorative since it would be visible to consumers. Decorative aluminium die casting offered an eye-catching design and provided the required rigidity and strength. <strong>Dynacast Elgin designed and manufactured three parts in total: a decorative aluminium die-cast shelf and two Multi-Slide zinc hinge components.</strong></p><h2>DYNACAST DELIVERS</h2><p>Dynacast strives to ensure every customer receives insight and expertise that adds value at every stage of the design and die cast manufacturing process. This is why today, across multiple industries and geographies, Dynacast is synonymous with precision-engineered metal components. <strong>Its extensive knowledge of metal die casting and reliable reputation made Dynacast a valuable partner for the appliance manufacturer.</strong></p>

Metal refrigerator with die cast metal cooling parts

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Discover how aluminium die casting can enhance energy efficiency while maintaining the strength and performance required for refrigerator appliance components.

Improve energy efficiency with aluminium die casting

Dynacast helped a leading appliance manufacturer enhance energy efficiency in a new refrigerator design by using aluminium die casting for a door-in-door feature, reducing cold air loss and lowering energy consumption.

Energy efficiency through aluminium die casting

<h2><strong>Mastering precision in die casting production</strong></h2><p>Whether you’re new to precision die casting or an experienced professional, understanding the latest advances in production die casting capabilities is essential for remaining competitive. In this on-demand webinar, Dynacast’s European <a href="/additional-capabilities/engineering" target="_self">engineering experts</a> explain how precision-driven processes can help you achieve superior quality, tighter tolerances and more efficient manufacturing outcomes.</p><p>Learn how Dynacast’s innovative approach enables the production of complex net-shape components with minimal draft angles—reducing secondary operations while maintaining exceptional accuracy and consistency across every part.</p><h4><strong>What you’ll learn:</strong></h4><ul><li>Advanced <a href="/die-casting-technologies" target="_self"><strong>die casting technologies</strong></a> used to improve precision and repeatability</li><li>The benefits of different <a href="/metals" target="_self"><strong>die cast metals</strong></a> and their performance characteristics</li><li>How Dynacast’s <strong>design capabilities</strong> support complex geometries and Multi-Slide tooling</li><li>Real-world <strong>case studies</strong> demonstrating efficiency and cost savings</li><li>Practical insights into optimising <strong>manufacturing quality and scalability</strong></li></ul><p><strong>Webinar</strong>: Precision in production: die casting capabilities</p><p><strong>Format</strong>: On-demand webinar</p><p><strong>Language</strong>: English</p><p>Watch now and discover how Dynacast’s precision die casting expertise can transform your production process — delivering stronger parts, faster turnaround and greater value.</p>

Assortment of aluminum metal parts for automotive applications

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Learn how precision die casting delivers complex geometries, tight tolerances and superior quality for more efficient manufacturing.

Precision in production: die casting capabilities

Bernd Froehlich

Sergio Perino

Christian Flich

Discover the advanced die casting technologies, material options and design capabilities in 'Precision in Production: Die Casting Capabilities 

<p>Dynacast, a Form Technologies Company, is a global manufacturer of precision engineered metal components. Using proprietary die casting technologies, we provide robust solutions for numerous industries, including automotive, consumer electronics and healthcare. </p><p>Every organisation we work with benefits from over 80 years of experience, innovation and techniques that have redefined the manufacturing industry. Dynacast operates 21 manufacturing sites in 16 countries and consistently delivers value through engineering expertise, efficient operations and Advanced Quality Planning systems.</p><p>Join us for the first instalment of the Dynacast Metal Solutions Webinar Series - Europe. In this webinar, our team will cover:</p><ul><li><a href="/metals" target="_self">Material options</a></li><li><a href="/die-casting-technologies" target="_self">Die casting technology</a></li><li><a href="/resources/article/the-future-of-die-casting-in-the-automotive-industry" target="_self">Showcase of innovations in die casting</a></li><li><a href="/resources?type=caseStudies" target="_self">Case studies</a></li><li>And more</li></ul><p>&nbsp;</p>

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Discover Dynacast's die casting technologies and how high-quality engineering, tooling and process controls contribute to superior components in manufacturing.

An introduction to precision die casting | Dynacast webinar

Join us for the Dynacast Metal Solutions Webinar Series - Europe as we explore material options, die casting technology and innovative precision die casting solutions, drawing on over 80 years' expertise to deliver cutting-edge insights and case studies. 

An introduction to precision die casting

Safety-critical tooling transfer

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Die casting tooling

Tooling solutions for every project

Multi-Slide die casting tooling

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Enhance your knowledge of Dynacast tooling

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