<p>In an industry driven by rapid innovation, our engineers excel at meeting critical time-to-market requirements with die casting solutions for consumer electronics.</p>

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Consumer electronics

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Our minimal-draft design capability enables intricate internal features to be cast directly, eliminating costly secondary operations and improving accuracy.

Complexity & accuracy

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Magnesium excels in handheld devices, offering lightweight, rigid RFI/EMI shielding with integrated electronic component features to meet stringent emission and interference standards.

Magnesium advantage

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From standard options such as gold and black anodising to specialised plating, we offer solutions to meet your exact requirements.

Custom surface finishes

Dynacast ensures that consumer electronics parts maintain rigidity while adding minimal weight, fulfilling thin-wall design requirements with optimal functionality and structural integrity.

Thin-wall engineering

Consumer electronics leaders choose Dynacast to help achieve key goals

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Industry-leading certifications

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<p>For over 25 years, Dynacast has set itself apart in the precision die casting industry through the innovation and performance of its <a href="/die-casting-technologies/multi-slide" target="_self">multi-slide technology</a>. Unlike traditional die casting processes, our proprietary approach allows us to design and build machines, tools and casting solutions tailored specifically to each customer’s unique requirements.</p><p>This flexibility enables us to deliver components with <strong>unmatched precision, quality and efficiency</strong>—a capability few others in the industry can offer.</p><h2>Design for Manufacturing (DFM)</h2><p>Our engineering team believes the most successful projects start with early collaboration. By involving our engineers during the design phase, we help customers take full advantage of <a href="/additional-capabilities/tooling" target="_self">multi-slide tooling</a> to achieve optimal manufacturability.</p><p>Multi-slide tooling provides far greater design flexibility through multiple directions of pull. This allows complex geometries to be cast directly into the part, often eliminating costly secondary machining or drilling operations.</p><p>For example, when producing a component with a through-hole, a multi-slide die casting tool can cast the hole directly into the part. Traditional tooling, on the other hand, would require post-casting drilling, adding time, cost and potential for variation.</p><p>By integrating DFM principles early, Dynacast helps customers minimise production steps, improve part consistency and reduce overall costs.</p><h2>Multi-slide tooling: precision and efficiency combined</h2><p>Our multi-slide die casting machines feature advanced thrusters, a flexible crosshead adaptor system and a rapid pneumatic injection system. Together, these technologies:</p><ul><li>Minimise part variation and dimensional deviation</li><li>Improve metal flow and fill speed</li><li>Reduce flash and porosity</li><li>Enable tighter process control across large production runs</li></ul><p>The result is a casting process capable of mass-producing small, intricate components with outstanding accuracy and surface finish. Multi-slide tooling ensures every part meets exacting tolerances while maintaining cost-efficiency at scale.</p><h3>Part improvement and superior consistency in part quality</h3><p>With Dynacast’s multi-slide die casting technology, manufacturers gain exceptional control over dimensional accuracy and surface finish, resulting in consistent, high-quality parts across every production run. Multi-slide tools are designed to achieve <strong>better part-to-part uniformity</strong> with <strong>tighter tolerances</strong>, typically around ±0.002 inches—less than half the variation seen in components produced using standard tooling.</p><p>This level of precision enables a wide range of <a href="/additional-capabilities/part-improvement" target="_self">part improvements</a>, including:</p><ul><li>The ability to <strong>cast thinner walls</strong> for reduced weight and material savings</li><li>More accurate casting of <strong>external and internal threads</strong></li><li>Enhanced <strong>surface quality</strong> with minimal porosity or flash</li><li><strong>Greater consistency</strong> between production batches, even at high volumes</li></ul><p>By combining precise tooling, optimised metal flow and process repeatability, Dynacast’s multi-slide process produces higher-quality components that require minimal finishing and assembly. We are able to cast external threads more precisely.</p><h3>Reducing costs and waste</h3><p>Traditional die casting tooling can be complex and expensive, particularly for parts that require multiple directions of pull or post-machining. Multi-slide technology solves these challenges by integrating those features into a single operation.</p><p>Key cost advantages include:</p><ul><li><strong>Lower tooling costs</strong>: Multi-slide tools can cost less than half of standard tools, thanks to their ability to cast complete features without secondary operations.</li><li><strong>Reduced waste</strong>: Smaller runners and overflows mean less excess material and lower scrap rates.</li><li><strong>Faster cycle times</strong>: Multi-slide systems fill and eject parts more quickly, improving throughput and reducing per-part cost.</li></ul><p>Depending on the part geometry, a multi-slide tool may have anywhere from <strong>five to seven slides</strong>, enabling complex shapes to be produced efficiently and consistently.</p><h3>Multi-slide die casting for complex components</h3><p>Dynacast’s multi-slide die casting process is the ideal solution for <strong>small, high-precision and geometrically complex components</strong>. It excels at producing <strong>net-shape or near-net-shape parts</strong>, including intricate internal and external threads without the need for secondary machining.</p><p>Applications span across industries such as:</p><ul><li>Automotive and EV components</li><li>Consumer electronics</li><li>Medical devices</li><li>Telecommunications hardware</li><li>Industrial equipment and connectors</li></ul><p>By combining innovation in tooling design with decades of process expertise, Dynacast continually improves the efficiency, speed and quality of its die casting operations, delivering the best parts possible with the most advanced technology available.</p><h2>Partner with Dynacast for advanced multi-slide solutions</h2><p>Dynacast’s proprietary multi-slide technology provides a unique competitive edge. It offers precision, consistency and cost savings that standard die casting methods can’t match.</p><p>Whether you need to optimise an existing component or develop a new design, our engineers can help you leverage multi-slide tooling to reduce costs, improve part quality and accelerate production.</p>

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Learn about the benefits of multi-slide die casting technology, from improved component design to greater production efficiency and meaningful cost savings.

Benefits of multi-slide die casting technology

Discover how Dynacast's multi-slide technology can reduce costs, improve quality and streamline your manufacturing process. 

Benefits of multi-slide technology

<p>The die casting process can offer significant advantages over other manufacturing processes—such as machining and stamping—resulting in major savings in unit price and overall production costs. With die casting, you can produce complex net-shape components, including intricate internal and external features with minimal draft angles—minimising secondary operations. However, as with any production process, there is much to consider before deciding which process is best suited to your component.</p><p>In January 2021, Form Technologies hosted the first instalment of the Metal Solutions Webinar Series – EU. This webinar, <a href="/resources/webinar/an-introduction-to-precision-die-casting" target="_self">An Introduction to Precision Die Casting</a>, presented by the European Dynacast team, aims to guide our customers in taking advantage of the benefits of die casting. Our webinars give attendees the opportunity to ask our experts questions about the die casting process during our live question-and-answer session. Take a look at some of the most frequently asked questions below.</p><h2>What is the minimum wall thickness for die cast components?</h2><p>The minimum wall thickness we can achieve depends on the part geometry and part design, but under ideal conditions, Dynacast can cast aluminium walls as thin as 0.3mm. Generally, a minimum wall thickness of 0.5mm – 1.0mm is advisable to maintain high strength.</p><h2>What is the ideal wall thickness for die casting?</h2><p>There is no single ideal wall thickness for a die cast component. Instead, maintaining consistent wall thickness and reducing weight where possible are extremely important for a strong, cost-effective component. The best way to achieve this is to incorporate optimised gate and overflow locations into your part design to avoid unnecessary porosity and maintain strength.</p><h2>What is the tightest tolerance Dynacast can hold?</h2><p>Dynacast takes pride in maintaining the tightest tolerances in the industry, but as with wall thickness, tolerance largely depends on part geometry. For the most exact tolerances, zinc can generally achieve between ±0.001” and ±0.002”, whereas aluminium can achieve between ±0.002” and ±0.004”.</p><p>However, although a tolerance of ±0.001” is possible with Dynacast, manufacturers must take care to avoid designing unnecessary cost into the component. Too often, companies request exacting tolerances and minimal draft angles when such features are not required to maximise part performance. As a result, their castings fail.</p><p>Instead, take a more holistic approach to your design. With the help of our <a href="/additional-capabilities/engineering" target="_self">die casting engineers</a>, identify the non-critical dimensions of your component to allow for wider tolerance zones. In addition to extending the life of your tool because there are fewer precise geometries subject to wear, allowing for tolerance zones also makes it easier to plan the tolerance stack-up of your entire component. This will help you avoid machining and secondary operations wherever possible, enabling your design to make the most of the die casting process.</p><h2>Which die cast metals are environmentally friendly to use and produce?</h2><p>All of the die cast materials we use—<a href="/metals/aluminum" target="_self">aluminium</a>, <a href="/metals/zinc" target="_self">zinc</a> and <a href="/metals/magnesium" target="_self">magnesium</a>—are environmentally friendly because they are recycled. At Dynacast, our plants operate in a closed-loop cycle, using advanced remelting capabilities to reuse any excess metal recovered from runner systems in the dies. After reclaiming the excess metal, Dynacast verifies its chemical composition using spectrometers to ensure it retains the physical and mechanical properties of newly sourced metal.</p><p>In production terms, aluminium is the most environmentally friendly of all die casting metals. Aluminium is 100% recyclable, and 75% of all the aluminium ever produced is still in use today. As aluminium can be recycled repeatedly without deterioration in its mechanical or physical properties, it can serve the same applications at the same level of performance as primary aluminium extracted directly from bauxite ore—all while positively affecting the environment and your bottom line.</p><p><em>The physical and mechanical properties of aluminium make it the ideal choice for parts used in almost any industry, including aerospace, defence, consumer electronics, healthcare, automotive and more. </em></p><h2>What are the benefits of die casting over screw machining?</h2><p>The benefits of die casting are largely associated with production speed and total unit price savings. Dynacast’s multi-slide machines can be designed with multiple cavities, enabling our engineers to cast extremely complex parts quickly. Our multi-slide die casting machines operate at speeds of up to 75 cycles per minute, delivering 4,500 shots per hour. In a two-cavity tool, this means 9,000 parts per hour.</p><p>A faster cycle time contributes to a lower overall cost per piece. Additionally, die casting tools enable unmatched complexity in internal and external geometries, resulting in fewer secondary operations. With multi-slide die casting, you can cast complex geometries that would otherwise need to be manufactured from two or more pieces and assembled using other processes.</p><p>While screw machining offers a lower upfront tooling cost, die casting more than compensates through overall unit price savings. For an ideal part—one that is small, high volume and can be cast in zinc—the tool is fully paid back somewhere between 10-14 months of production. Every part produced after that contributes to your bottom line.</p><h2>Do you have materials that are corrosion resistant without surface treatment?</h2><p>The level of environmental resistance provided depends on the material and your project requirements. Zinc, for example, is relatively resistant in comparison with aluminium alloys, although some zinc oxide, or white rust, may occur. However, if you require a high level of environmental resistance for your die cast component, we recommend using one of our surface treatments—from treatments and coatings that provide corrosion resistance, high-gloss finishing, painting and more.</p><h2>How can you determine whether die casting is cost-effective compared with other fabrication processes?</h2><p>The cost-effectiveness of the die casting process must be evaluated on a case-by-case basis. In many cases, converting from screw machining, machining from solid, stamping or welding to die casting results in better part performance and lower costs at full-scale production. However, we invite you to contact an engineer to determine whether converting to die casting is the best solution for you.</p><p>With over 80 years of experience, Dynacast consistently delivers value through engineering expertise, efficient operations and Advanced Quality Planning systems. </p>

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Find answers to common precision die casting questions, including advantages, tolerances, materials and design flexibility for cost-effective production.

Precision Die Casting FAQs | Dynacast Guide

Explore the benefits and considerations of precision die casting, addressing common questions to help manufacturers optimise production and cost efficiency. 

An introduction to die casting: frequently asked questions

<p><strong>Discover the Secrets Behind Award-Winning Die Cast Design</strong></p><p>Join some of the industry’s leading die cast design engineers in our exclusive <strong>Die Cast Design Roundtable</strong>, where Dynacast’s multi award-winning engineering team shares insights on creating parts that set the standard for excellence in precision manufacturing.</p><p>See how Dynacast’s engineers combine innovation, expertise, and advanced tooling to create some of the most precise and efficient die cast components in the industry.</p><p>In this on-demand session, you’ll learn:</p><ul><li>How our <strong>Design for Manufacturability (DFM)</strong> approach improves part quality, reduces costs, and accelerates production</li><li>Real-world examples from <strong>NADCA Award-winning projects</strong>, including what made them stand out from the competition</li><li>Proven strategies for optimising <strong>tooling, tolerances, and material flow</strong> to achieve superior casting performance</li><li>Expert guidance on avoiding common design pitfalls and maximising the potential of <strong>multi-slide and conventional die casting</strong></li></ul><p>Watch now to explore this year’s award-winning design and elevate your next project with Dynacast’s proven engineering excellence.</p>

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Gain expert insights into die casting design challenges and practical, proven solutions for complex, high-precision manufacturing projects.

Insights from the Die Cast Design Roundtable

Access our on-demand Die Cast Design Roundtable to hear insights from award-winning design engineers on creating optimal die castings, including a showcase of this year's award-winning design. 

Consumer electronics

Consumer electronics leaders choose Dynacast to help achieve key goals

Complexity & accuracy

Magnesium advantage

Custom surface finishes

Thin-wall engineering

Industry-leading certifications

An overview of
consumer electronics applications

BEYOND THE BASICS

Expand your knowledge of die casting for consumer electronics

Article

Article

Webinar

Interested in starting your die casting project?

Consumer electronics

Consumer electronics leaders choose Dynacast to help achieve key goals

Complexity & accuracy

Magnesium advantage

Custom surface finishes

Thin-wall engineering

Industry-leading certifications

An overview ofconsumer electronics applications

BEYOND THE BASICS

Expand your knowledge of die casting for consumer electronics

Article

Article

Webinar

Interested in starting your die casting project?

An overview of
consumer electronics applications