<p>Dynacast offers scalable production capabilities and versatile expertise in handling complex designs, ensuring the manufacture of durable components that meet stringent quality standards across the hardware industry.</p>

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Hardware

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Metal hardware outperforms plastic in durability and strength. Die casting offers superior alloys with resistance to wear, corrosion and breakage.

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Dynacast’s die casting capabilities ensure precise dimensions and tight tolerances for reliable functionality in hardware components.

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Our die cast alloys, such as aluminium, magnesium and zinc, offer significant weight-reduction benefits essential for hardware applications such as portable tools. 

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Die casting enables rapid production of large quantities of identical parts required for hardware applications such as hinges, brackets and tool housings. 

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Hardware leaders choose Dynacast to help achieve key goals

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<p>Facing plant closure, a hardware and security products manufacturer required a rapid, efficient die casting tooling transfer. Outdated equipment, high labour costs and inefficient tooling utilisation at the 50-year-old facility made this transition critical to minimise downtime and maintain product quality.</p>

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The problem

<p>Dynacast minimised die cast production downtime through a robust tooling transfer process. Key elements include:</p><p>&nbsp;</p><ul><li><strong>Thorough tooling assessment</strong></li><li><strong>Refurbishment &amp; reverse engineering</strong></li><li><strong>Optimisation</strong></li><li><strong>Structured project management</strong></li><li><strong>Streamlined sampling &amp; secondary operations</strong></li></ul>

A streamlined tooling transfer process

<p>Leveraging our global resources, we quickly provided support and flexibility. Compatibility with the customer's existing equipment enabled rapid deployment, bringing the machine into operation within days. Focusing on the project's needs, we prioritised current medium-to-low-volume parts while considering future high-volume potential.</p>

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<h1>Advancing Precision Die Casting With the A3 Series</h1><p>Dynacast's commitment to precision, innovation, and quality drives everything we do. One of the pillars of this commitment is our <a href="/die-casting-technologies/multi-slide" target="_self">proprietary Multi-Slide technology</a>, which enables the production of complex, high-quality metal components with exceptional accuracy and efficiency.</p><p>While our A2 machines have long been recognised for their speed and precision, the A3 die casting machines push performance even further, offering enhanced versatility, larger die capacity, and improved cycle times. This article explores the A3 SIS and A3 MAG SIS models and how they are setting new standards in small-part metal and magnesium die casting.</p><h2>A3 Machine Capabilities</h2><p>Dynacast’s A3 machines are designed to deliver high-speed production, tight tolerances, and consistent quality, even in the most complex geometries.</p><p>Our Multi-Slide technology enables faster cycle times by allowing multiple slides to operate independently, significantly improving the efficiency of part ejection and die filling. This results in:</p><ul><li>&nbsp;Shorter production cycles</li><li>Fewer secondary operations</li><li>Reduced material waste</li><li>Greater design flexibility</li></ul><p>The A3 platform is ideal for industries requiring precision micro-components, such as automotive electronics, telecommunications, medical devices, and consumer products.</p><h2>A3 SIS: Superior Injection System for Enhanced Productivity</h2><p>Introduced in 2010, the A3 SIS (Slide Injection System) machine was engineered for greater speed, strength, and reliability. It features a reinforced main plate with 28 tons of locking force, providing the stability needed for precision casting.</p><h3>Key Specifications and Features:</h3><ul><li><strong>Die size: </strong>Up to 160 x 140 mm</li><li><strong>Shot weight: </strong>Up to 180 grams</li><li><strong>Locking force: </strong>28 tons</li><li><strong>Slides: </strong>Supports four slides plus additional integrated options</li></ul><p>The SIS injection system offers several competitive advantages:</p><ul><li><strong>Faster cycle times: </strong>Rapid injection and cooling enable higher output levels.</li><li><strong>Higher cavity capacity: </strong>Produces more parts per cycle, improving efficiency.</li><li><strong>Improved surface finish: </strong>Reduces porosity and enhances surface quality.</li><li><strong>Complex part design capability: </strong>Multiple slides allow intricate geometries and undercuts.</li></ul><p>The A3 SIS is ideal for zinc and aluminium alloy components where surface finish, precision, and consistency are essential.&nbsp;</p><h3>A3 MAG SIS: Precision for Magnesium Alloy Components</h3><p>The A3 MAG SIS builds on the proven foundation of the A3 SIS, but it is specifically engineered for magnesium die casting applications. It includes a two-chamber melting pot designed to handle magnesium’s unique properties safely and efficiently.</p><h3>Key Benefits and Features:</h3><ul><li><strong>Dedicated magnesium system: </strong>Ensures safety and compliance with CE safety standards.</li><li><strong>Two-chamber melting pot: </strong>Enhances temperature control and casting consistency.</li><li><strong>No machining required: </strong>Produces net-shape or near-net-shape components.</li><li><strong>Superior part quality: </strong>Enables thinner walls, tighter tolerances, and minimal porosity.</li><li><strong>Optimised for small magnesium parts: </strong>Perfect for lightweight, high-strength components.</li></ul><p>By eliminating much of the secondary machining required in traditional magnesium die casting, the A3 MAG SIS reduces both production time and cost, making it an exceptional solution for industries such as aerospace, automotive, and consumer electronics.</p><h2>Why Choose Dynacast's A3 Die Casting Machines</h2><p>Choosing the right die casting technology is crucial for manufacturers seeking to optimise production without sacrificing quality. The A3 series delivers on every front:</p><ul><li><strong>Unmatched precision </strong>in complex geometries</li><li><strong>Faster cycle times </strong>and reduced operational costs</li><li><strong>Scalability </strong>for both small and medium production runs</li><li><strong>Compatibility </strong>with multiple alloys, including zinc, aluminium, and magnesium</li><li><strong>Reliability and global support </strong>through Dynacast's worldwide network</li></ul><p>Dynacast’s A3 die casting machines exemplify how advanced engineering and proprietary technology can redefine what is possible in precision metal casting. Whether producing miniature zinc connectors or lightweight magnesium housings, the A3 SIS and A3 MAG SIS deliver superior performance, quality, and cost-efficiency that empower manufacturers to stay ahead in competitive markets.</p>

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Learn how A3 die casting machines increase flexibility in part size, reduce cycle times, and maintain precision when producing larger, complex components.

Benefits of A3 Die Casting Machines | Dynacast

Discover how Dynacast's A3 die casting machines deliver superior part quality, faster production, and greater complexity compared with traditional methods. 

Benefits of A3 Die Casting Machines

<p>When considering aluminium die casting, it is often associated with large components requiring relatively thick wall sections. Advances in casting technology now make it possible to produce aluminium parts that are nearly as lightweight as their magnesium counterparts, while also delivering additional benefits such as higher tensile strength and a wider range of finishing options. Historically, design engineers have avoided <a href="/metals/aluminum" target="_self">aluminium die casting</a> due to the need for thicker wall sections (typically 1.5 mm – 2.0 mm), which resulted in heavier parts.</p><p>A common question in die casting is: <em>Why is it difficult to cast aluminium with thin walls?</em> The relatively high melting and solidification temperatures of aluminium mean that when molten metal is injected into a die, it begins cooling and solidifying very rapidly. The transition window between the liquid and solid states is extremely narrow, requiring a fill time of less than 30 milliseconds to achieve thin-wall features (0.5 mm – 1.0 mm). Our engineers address this challenge through highly precise process control—even minor adjustments across more than a dozen variables can determine the difference between success and failure. Tooling design is equally critical. Dynacast's tooling engineers carefully balance runner and gate design, overflow placement and design, and targeted thermal management to ensure optimal outcomes.</p><p><strong>Not interested in aluminium? Try our </strong><a href="/metals/metal-selector-tool" target="_self"><strong>dynamic metal selector tool</strong></a><strong> to compare the mechanical and physical properties of other alloys.</strong></p><h2>Evolution of thin-wall aluminium technology</h2><p>Historically, to cast aluminium with thin-wall sections, we would have used custom-formulated high-fluidity alloys. Our engineers recently developed a method to apply this technology to standard alloys. By using improved process control, state-of-the-art tooling design, and machine enhancements, we fundamentally changed the die casting industry forever.  </p><h2>Benefits of thin-wall aluminium die casting</h2><p>One of the most significant benefits of thin-wall aluminium die casting is the ability to produce lighter components while also enabling a wider range of surface finishing options compared with other die-casting alloys. Reducing wall thickness from 2.0 mm to 0.5 mm results in a 75% weight reduction—a substantial advantage when reducing mass in applications such as <a href="/industries/automotive" target="_self">automotive components</a> or handheld electronic devices. In addition, aluminium can withstand the highest operating temperatures of all die-casting alloys. Cast aluminium also offers versatility and corrosion resistance, retains high dimensional stability even with thin walls, and is suitable for use across a broad range of industries.</p>

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Discover how thin-wall aluminium die casting reduces weight, maintains strength and improves precision for complex, high-performance engineered components.

Thin-wall aluminium die casting | Dynacast

See the process for casting aluminium with thin walls, producing lighter, more versatile components. 

Die-cast aluminium with thin walls

<p>Zinc-aluminium alloys were first introduced for gravity casting but are now sought-after materials for high-pressure, cold-chamber die casting. With zinc as the base metal, ZA-27 consists of 27 percent aluminium and 2.2 percent copper. ZA alloys have higher concentrations of aluminium than traditional zinc alloys and have unrivalled bearing properties—ZA-27 having the highest aluminium content of all three ZA alloys. Silver in colour, this zinc-aluminium combination is lightweight, dense and best suited to applications requiring optimum strength.</p><h2>Benefits of ZA-27</h2><p>ZA-27 provides a variety of benefits and solutions for different die casting projects. In addition to its wear resistance and high-strength properties, other specific benefits of ZA-27 include:</p><ul><li>High tensile &amp; yield strength</li><li>Corrosion resistance</li><li>Non-sparking properties</li><li>Hardness</li><li>Good bearing and creep properties</li><li>Lightweight</li><li>Easy machinability</li><li>Thermal conductivity</li><li>Longer tool life</li><li>Environmentally friendly and efficiently recyclable</li></ul><h2>ZA-27 applications</h2><p>ZA-27 is an underappreciated metal for foundry applications. It is three times stronger than typical cast aluminium and can have the tensile strength of grey cast iron. At Dynacast, we have had great success casting ZA-27. One of our customers—in the safety restraint industry—needed more strength than standard aluminium alloys could offer. Our team of engineers designed the part using ZA-27 and achieved the maximum strength required without failure.</p><p>ZA-27 can be used for a variety of projects but is best suited to bearing applications. It is easily machined, and castings can be readily polished, plated, painted or anodised. Due to its high melting point, ZA-27 is suitable for projects with service temperatures of ~150 degrees Celsius. ZA-27’s non-sparking characteristics enable it to function as a natural bearing, which inevitably provides cost savings as well as maintenance and reliability advantages over other cast metals—making it ideal for the <a href="/industries/automotive" target="_self">automotive industry</a>. Other industries using ZA-27 include:</p><ul><li>Aeronautics</li><li>Agricultural machinery</li><li>Construction and building</li><li>General engineering</li><li>Textile machinery</li></ul><p><strong>Try our </strong><a href="/metals/metal-selector-tool" target="_self"><strong>dynamic metal selector tool</strong></a><strong> to compare the mechanical and physical properties of different alloys.</strong></p><h2>Die casting with ZA-27</h2><p>The high-strength properties of ZA-27, combined with its castability, enable our team of engineers to design for strength while reducing the overall material content compared with alternative materials. We can cast stronger parts with thinner walls using ZA-27. Customers whose parts failed when using A380 switched to ZA-27 and more than doubled their yield strength. Our team of engineers has the experience and expertise to guide you through transitioning your project to ZA-27 or assist you in starting a new project from scratch. </p>

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Explore the distinctive properties of ZA-27 alloy for die casting, delivering high strength and excellent wear resistance in demanding industrial applications.

ZA-27 die cast parts | material spotlight

ZA-27, a zinc-aluminium alloy, offers high strength, corrosion resistance and non-sparking properties, making it ideal for bearing applications, automotive parts and other industries. 

Material spotlight: ZA-27

The big shift: how we transferred 80+ tools

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<h2>Design engineering is changing, and it’s changing fast.</h2><p>Today’s die casting engineers are under considerable pressure to develop viable components quickly and more efficiently than ever before. And <a href="/additional-capabilities/engineering" target="_self">Design for Manufacturing (DFM)</a> discussions with your supplier are among the best practices engineers use to ensure proof of concept, <a href="/additional-capabilities/part-improvement" target="_self">part optimisation</a> and scalability.</p><p>Defining a successful plan and process for your part is just as important as the component itself. The design is crucial to the entire production process—and affects everything from material cost to time-to-market.</p><p>In this webinar, <strong>Design for Manufacturing: a critical step for successful production, </strong>Dynacast’s Senior Application Engineer, Max Gondek, discusses the benefits of working with an engineer early in the design phase of your die-cast part. He covers:</p><ul><li>How to reduce component weight</li><li>Why wall thickness increases cost</li><li>How to determine the best draft angle for your part</li><li>How to strengthen your casting with fillets and radii</li><li>And many more design tips!</li></ul><p>&nbsp;</p><p><strong>Complete the form to register for our free webinar.</strong></p>

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Discover how Design for Manufacturing (DFM) improves quality, lowers costs and increases efficiency across every stage of die casting production and launch.

DFM: key to successful die casting production

In this on-demand webinar, Dynacast’s Senior Application Engineer, Max Gondek, outlines essential Design for Manufacturing (DFM) strategies for optimising component design, reducing costs and improving production efficiency through early collaboration with engineers. 

DFM: a critical step for successful production

<p>Traditionally, stainless steels were thought to be the only material that would meet FDA approval for manufacturing biocompatible medical devices. However, innovations in die casting surface treatments allow medical manufacturers to choose from a variety of <a href="/additional-capabilities/surface-finishes-and-plating" target="_self">specialised coatings and surface finishes</a> to meet the rigorous testing and validation required by the FDA/EMEA. Today, you do not have to limit your material choice to one or two options. With Dynacast surface treatments, you can benefit from the speed and cost savings of zinc Multi-Slide or our thin-wall aluminium casting while remaining compliant with the FDA.</p><h2>Anodised aluminium for medical castings</h2><p>Aluminium is often chosen for many applications because of its weight-to-strength ratio, relatively low manufacturing cost and ability to be coloured, while maintaining a high degree of thermal conductivity. Medical and healthcare manufacturers can benefit from aluminium in external medical applications by using surface finishes that provide optimal biocompatibility.</p><p>In the <a href="/industries/medical" target="_self">medical industry</a>, the process of anodising aluminium is often an important first step that enables other necessary surface treatments and enhances the material’s durability and corrosion resistance. Anodising is an environmentally safe electrochemical process that changes the surface of aluminium into porous aluminium oxide, creating an end product whose finish is more receptive to colouring or protective coatings such as parylene. In healthcare, this means anodised aluminium medical equipment will last longer and can be manufactured to meet biocompatibility regulations.</p><h2>Parylene surface finish</h2><p>Parylene has been used as a stable surface treatment for medical equipment for decades. This reliable protective coating is biocompatible and conforms to USP Class VI and ISO 10993 standards. It is transparent, pin-hole-free and conforms exactly to the features of any surface. Parylene coats extremely consistently and thinly (as thin as 0.0005”), providing coverage even in the most complex geometries, while adding very little weight or volume.</p><p>These features make parylene an ideal coating for zinc and aluminium die-cast medical components. The die casting process offers many advantages over machined components, including unmatched strength and precision, as well as cost savings. Adding parylene allows medical manufacturers to benefit from die casting without sacrificing compliance or complexity.</p><h2>E-coating and conversion coating (Chem film)</h2><p>Conversion coating, or chem film, is an FDA/NSA-approved treatment process for aluminium medical components. Conversion coating produces a conductive protective coating without dimensional change, enhances corrosion resistance and improves adhesion for paint finishes. E-coating provides medical devices with a cosmetic finish and an additional layer of protection. Much like anodising, e-coating and conversion coating surface treatments extend the durability of medical equipment while meeting FDA regulations. Like parylene, conversion coating is extremely thin (with a thickness of less than .000001”), so complex geometry does not need to be sacrificed.</p><h2>Improving your surface finish with Dynacast</h2><p>Healthcare providers are responsible for improving patients’ conditions, while medical manufacturers are responsible for improving the tools used to serve patients effectively. Depending on your project requirements, several biocompatible surface treatments and finishes are available, allowing you to benefit from the die casting process and alloys.</p><p>While anodised aluminium, parylene and conversion coating are excellent options for metal medical components requiring greater biocompatibility, several other options are available for parts subject to less stringent regulations. At Dynacast, we have experience solving problems and engineering solutions for the medical industry, including streamlining FDA validation.</p>

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Discover how Dynacast applies biocompatible finishes to produce safe, durable medical-grade die castings for surgical instruments and diagnostic devices.

Medical-grade die castings | Surface treatments

See how advanced surface treatments such as anodising, parylene coating and conversion coating enable medical manufacturers to use die-cast materials such as aluminium and zinc, ensuring biocompatibility while meeting FDA regulations and enhancing product durability.

Biocompatible surface treatments for medical-grade die castings

<h2>Choosing the right process for your metal component</h2><p>If you’re considering screw machining or die casting for your next part, your project probably requires tight tolerances, short lead times and high production volumes. These characteristics make a part a viable candidate for either process.</p><p>Although precision metal components can be produced through both processes, the choice often comes down to efficiency and cost—which production process will add more value to your project? In this blog, we’ll cover the respective benefits of screw machining and die casting, and what you stand to gain by converting your precision component from screw machining to die casting.</p><h2>Benefits of screw machining</h2><p>Screw machining offers two main benefits.</p><p>The first is that screw machining enables you to manufacture steel alloys that cannot be die cast. <a href="/additional-capabilities/tooling" target="_self">Die casting tooling</a> is made from hardened steel to withstand the high pressure and heat of the die casting process. Since aluminium and zinc have significantly lower melting temperatures than steel, these metals do not fuse with the steel tool. Attempting to die cast a steel component, on the other hand, would produce one large mass of fused steel.</p><p>The second benefit is that screw machining can achieve tight tolerances with a lower initial tooling cost. CNC machining of any type is sometimes considered capable of achieving the tightest tolerances of any manufacturing process.</p><p>While it is true that machining produces tight tolerances and precise parts, Dynacast engineers maintain that die casting can produce parts with almost equal precision and greater complexity at a lower unit price, more quickly. When efficiency and cost are factors in your decision, the benefits of die casting will consistently outweigh those of screw machining.</p><h2>Benefits of die casting</h2><p>The benefits of die casting are largely associated with production speed and unit cost savings.</p><p>Dynacast’s Multi-Slide machines can be designed with multiple cavities, enabling our engineers to cast highly 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. In addition, die casting tooling enables unmatched complexity in internal and external geometries, resulting in fewer <a href="/additional-capabilities/secondary-operations" target="_self">secondary operations</a> associated with die casting. 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 up-front tooling cost, die casting more than compensates through overall unit cost savings. For an ideal part (one that is small, high volume and can be cast in zinc), the tooling cost is fully recovered somewhere between 10-14 months of production. Every part made after that contributes to your bottom line.</p><p><strong>Would you like to know whether your currently selected alloy can be converted to a zinc alloy with similar properties? Consult our interactive metal selector tool, or ask one of our engineers.</strong></p><h2>What do you gain by converting from screw machining to die casting?</h2><p>Perhaps you currently manufacture your precision metal component by screw machining. While this can effectively produce a complex part, our <a href="/additional-capabilities/engineering" target="_self">die casting engineers</a> recognise the limitations of screw machining compared with die casting. In addition to offering greater efficiency at a lower overall unit price, die casting also provides greater design freedom, tight tolerances and reduced material waste.</p><h3>Available capacity for parts that cannot be screw machined</h3><p>One of the greatest advantages of converting from screw machining to die casting is that die casting enables you to produce shapes that cannot be achieved through screw machining. When using screw machining as a manufacturing process, you are limited to parts that can be machined from bar or tubular stock on a rotating axis. Parts requiring complex internal geometries or dissimilar features are virtually impossible to produce by screw machining.</p><h3>Tight tolerances, faster</h3><p>When converting to die casting, design engineers are often concerned that die casting will not be able to achieve tolerances as tight as those of screw-machined parts. Generally speaking, if screw machining is performed slowly enough, the achievable tolerances are unmatched. However, taking the time to do so slows the entire production process, and often the tolerance required by a project can be achieved through Multi-Slide die casting.</p><p>Any compromises for tight tolerances are minor. Multi-Slide die casting produces precision components with tolerances of +/-0.02mm. With Dynacast, design engineers can work with customers to refine the part design for optimal manufacturability, delivering faster cycle times and improved part performance.</p><p>&nbsp;</p><iframe src="https://www.youtube.com/embed/NjduJayWpL0" width="560" height="315" title="Multi-Slide die casting process | Dynacast die casting" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen=""></iframe><h3><br />Reduce scrap and raw material waste</h3><p>Finally, converting from screw machining to die casting drastically reduces wasted material.</p><p>Screw machining works by cutting material away from a solid piece of metal or tubular stock. This means that, as the customer, you pay for <em>all</em> the raw material that goes into the tubular stock, not just the material in the finished part. You are paying for the wasted metal that ends up on the floor.</p><p>In contrast, in a four-cavity die casting tool, the gating system produces only waste roughly the size of the tab on a pen cap. By using die casting, you reduce waste and additional costs while improving your overall yield.</p><p>Die casting is ideally suited to high-volume projects requiring tight tolerances and rapid delivery.&nbsp;</p>

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Compare die casting and screw machining to identify the most cost-effective, efficient process for your precision metal component manufacturing requirements.

Die Casting vs. Screw Machining | Choose the Right Process

Explore the key differences between die casting and screw machining to determine which process offers greater efficiency, cost savings and design flexibility for your precision metal components, and discover the benefits of converting from screw machining to die casting. 

Hardware

Hardware leaders choose Dynacast to help achieve key goals

Material durability

Dimensional accuracy

Lightweight properties

High production rates

Industry-leading certifications

A look at
hardware applications

REAL RESULTS

The big shift: how we transferred 80+ tools

BEYOND THE BASICS

Expand your knowledge of die casting for hardware

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Article

Article

Global reach, local expertise

Interested in starting your die casting project?

Hardware

Hardware leaders choose Dynacast to help achieve key goals

Material durability

Dimensional accuracy

Lightweight properties

High production rates

Industry-leading certifications

A look athardware applications

REAL RESULTS

The big shift: how we transferred 80+ tools

BEYOND THE BASICS

Expand your knowledge of die casting for hardware

Webinar

Article

Article

Global reach, local expertise

Interested in starting your die casting project?

A look at
hardware applications