Advanced prototyping for components and tooling, globally sourced for optimal results

At the forefront of rapid prototyping for mass-production die-cast components, our capabilities ensure functional prototypes.

Female Dynacast engineer using protyping machines

Dynacast_Additional Capabilities_Prototyping_Engineer.jpg

Prototyping

Speak to an engineer

Dynacast uses machining from bar stock to tailor prototypes with mechanical properties that replicate those of alloys used in die casting and ensure accurate testing.

Metal part in the engineering prototyping lab

Dynacast_Additional Capabilities_Prototyping_Part.jpg

Customised prototyping

We rapidly develop single-cavity tooling using rapid prototyping and high-speed machining techniques, ensuring quick turnaround times.

Dynacast_Additional Capabilities_Prototyping_Design.jpg

Efficient tooling

We create master models for cost-effective gravity-cast and plaster-moulded prototypes in zinc, aluminium and magnesium, catering to diverse project needs.

Metal parts stacked together to be shipped

Dynacast_Extras_Metals 5.jpg

Cost-efficient

Our design engineers specialise in prototyping across industries, enabling us to optimise your manufacturing process for precision metal components.

Employee hanging parts for the surface finish to dry

Dynacast_Extras 2.jpg

Industry experts

Rapid prototyping for accelerated project success

Develop your part with our comprehensive range of prototyping solutions.

Large Square Card_Zinc.jpg

Learn more

Spin casting uses centrifugal force to create castings from a rubber mould. It is ideal for rapidly prototyping small parts with complex geometries and intricate wall designs.

Spin casting

Large Square Card_Magnesium.jpg

Machining from bar stock tests the ultimate strength of your final die casting, making it ideal for projects under time constraints. 

Machining from solid

Large Square Card_Aluminum.jpg

Streamline your design process with a versatile prototyping tool compatible with any material, eliminating the need to invest in multiple prototyping tools.

Multi-metal tooling

Investment casting can provide a fully functional prototype of your die-cast component in a variety of customisable alloys.

Investment casting

Prototype to production

See all resources

Designed for speed, agility, and flexibility, the 115,000 square foot die casting plant manufactures more than 144 million parts a year for a number of industries including <a href="/industries/automotive" target="_self">automotive</a>, <a href="/industries/consumer-electronics" target="_self">consumer electronics</a>, <a href="/industries/hardware" target="_self">hardware</a>, <a href="/industries/enterprise-technology" target="_self">telecommunications</a>, and <a href="/industries/medical" target="_self">healthcare</a>—and it does so with low-cost energy. In the spring of 2016, Dynacast Lake Forest initiated an energy project that utilises Tesla’s PowerPack batteries. The modular battery blocks store energy for the plant to use on demand during peak hours and are integral to its overall green initiative. During this same time, Dynacast Lake Forest opened a state-of-the-art manufacturing facility in Tijuana, Mexico that serves as an extension of the Southern California plant.Contact our team of engineers today to learn more about our multi-slide technology.<h2>Speed and agility</h2>Dynacast Lake Forest is not only <a href="/about-us/sustainability" target="_self">conscious of its energy consumption</a>, but is also constantly improving its lean manufacturing process. Its facility optimisation layout is a carefully considered plan for storage and production that standardises the precision die casting process. Its melt-at-the-machine process limits waste and allows it to work with a wider selection of materials, including K-Alloy, ZA-27, 413, and 360. Dynacast Lake Forest focuses primarily on multi-slide zinc, 80T – 200T conventional zinc, and 135T – 500T aluminium die casting.The experienced management and operations team has reviewed every aspect of the manufacturing process with a focus on improvement and modernisation. Lake Forest is committed to creating the highest-quality parts with the least possible waste, beginning with material flow.<h3>Design &amp; tooling in Lake Forest</h3>Dynacast Lake Forest has an experienced engineering and tooling team—several with tenure of over 25 years—with global resources readily available to tackle any project. Using the PRO-E design automation software and MAGMA mould-flow simulation, the team is committed to designing the best possible component while also providing full DFM to ensure parts will succeed in mass quantities. Its in-house toolroom is an added advantage; with CNC milling, EDM, wire EDM, and grinding equipment on-site, tools can be repaired faster and projects can be delivered on time.<h3>Secondary operations &amp; quality control</h3>As labour costs in Asia rise, the new Tijuana facility provides further access to skilled labour in Mexico for <a href="/additional-capabilities/surface-finishes-and-plating" target="_self">metal finishing</a> and <a href="/additional-capabilities/secondary-operations" target="_self">secondary operations</a>, including CNC machining, tapping, reaming, and drilling. With a dynamic and highly skilled workforce in Mexico and Southern California, Dynacast Lake Forest is able to provide better service and state-of-the-art technology to new and existing customers. The Southern California facility hosts a local, high-tech supply base that was once a legacy of the aerospace industry, leaving experienced platers and secondary operations in the area and providing a more cost-effective part price for Lake Forest customers.Post-casting, the Lake Forest team has the knowledge and tools to complete all final product testing, including electrical, RF, and leak testing. They are capable of visually inspecting parts with high-speed cameras and X-rays. They also have a state-of-the-art ultrasonic DÜRR advanced cleaning system that leaves parts with an organic residue of &lt;100µg and metallic particle sizes &lt;400µm. The alcohol-based solvent has a cycle time of 1.57 seconds per part. This step is imperative for customers with stringent cleanliness requirements.<h2>Putting Lake Forest to the test</h2>Dynacast Lake Forest delivers precision die casting services to a variety of industries, each with unique requirements and design needs. It is known for adapting its processes and creating new designs to manufacture even the most complex parts. For example, a high-end golf club manufacturer wanted to create an innovative putter. The Dynacast Lake Forest engineering team assisted with the part design and created the putter-head components using multi-slide ZA-8 and cold chamber ZA-27, which provided the ideal densities required for the final product. Lake Forest was the only die caster in North America that had the ability to cast both multi-slide ZA-8 and cold chamber ZA-27. Apart from material selection, the customer also valued Lake Forest’s proximity to its headquarters in Carlsbad, California, which allowed seamless collaboration between the engineering teams to refine the part geometry for mass production in real time. The customer’s contract manufacturer and plater were both based within a 100-mile radius of the plant, which helped to reduce cost.Another Dynacast Lake Forest customer required a highly cosmetic polished part. The well-known electric car company wanted to give its drivers an experience like no other—a polished metal handle. The mirror-like cosmetic finish is not an easy task, but with its network of certified polishing and plating vendors, Dynacast Lake Forest was able to provide the required quality service and high-volume capacity within a short distance of the Lake Forest plant. <h2>All-in die casting manufacturer</h2>With a dynamic local and international customer base, Dynacast Lake Forest continues to improve its facility and manufacturing processes to provide the best service and part design for any industry. Its success over the years can be attributed to its experienced management team, which continues to provide valuable resources and programme management, as well as its dedicated engineering team, which provides innovative and cost-effective tool and part designs. With the addition of the Tijuana plant and the Tesla power system, Dynacast Lake Forest has proven its commitment to creating an unmatched die casting business that will be more competitive than ever in the coming years.

Sustainability with solar panels on lake forest rooftop

Dynacast_About_Sustainability_Building.jpg

Discover Dynacast Lake Forest's advanced facility capabilities, providing precision die casting solutions for diverse industries, applications and requirements.

Dynacast Lake Forest facility spotlight | Die casting

Dynacast Lake Forest is a leading precision die casting company known for its speed, agility, and commitment to sustainability and customer satisfaction. 

Facility spotlight: Lake Forest

Die casting is a highly efficient and precise manufacturing process capable of producing complex metal components across industries. Achieving the best results starts with a well-optimized <a href="/additional-capabilities/part-improvement" target="_self">part design</a>. The following guidelines highlight key die casting design principles that enhance performance, manufacturability, and cost efficiency.<h2>Key Die Casting Variables</h2>DraftIncorporating draft angles — a slight taper on part walls — is essential for smooth part ejection and to account for material shrinkage. A draft angle between ¼ to 1 degree per side is generally recommended, though the exact amount varies based on the alloy and casting process.Fillets and RadiiGenerous fillets and radii strengthen parts, improve metal flow, and simplify finishing. Rounded edges reduce stress concentrations and improve part durability, making them a critical element in every die cast design.Ribs and BossesRibs and bosses reinforce parts without adding unnecessary weight. Ensure they integrate smoothly with fillets and radii to avoid sharp transitions. Applying draft to non-critical surfaces helps improve tool life and facilitates metal flow during casting.PocketsAdding pockets within solid sections reduces part weight and shortens cycle time. Maintain consistent draft angles and radii within pocketed areas to prevent stress points and ensure proper ejection.Optimizing Material FlowEffective metal flow design ensures uniform filling and reduces defects. Parts should feature smooth corners, rounded holes, and even wall thicknesses. Avoid long, narrow slots or abrupt changes in geometry that restrict metal flow and increase porosity risk.<h3>Additional Design Considerations</h3>Maximize the potential of the die casting process by integrating functional and aesthetic design features, including:<ul><li>Company logos or brand marks</li><li>Surface textures or decorative finishes</li><li>Integrated fasteners or attachment points</li><li>Embossed or recessed part numbers</li></ul>For parts with intricate geometries, Dynacast’s <a href="/die-casting-technologies/multi-slide" target="_self">multi-slide die casting technology</a> provides unmatched flexibility and precision, enabling complex designs with minimal secondary operations.<h2>Partnering for Optimized Die Casting Design</h2>Dynacast’s Design for Manufacturing (DFM) services help engineers refine designs for better performance, reduced waste, and cost-effective production. Our experts collaborate closely with customers to ensure each component meets functional requirements while maximizing manufacturability and consistency.

Dynacast_Resources_Surface Finishes

Enhance die casting efficiency and part quality with Dynacast's expert design tips, focusing on manufacturability, consistency and cost-effective production.

Design Tips for Improved Die Casting | Dynacast Article

See essential design tips for optimizing die casting parts.

Design Tips for Improved Die Casting

Your largest component production costs should not go to waste.Yet that is the outcome of many secondary operations—in fact, up to 80% of a component’s cost can be attributed to secondary operations that can be made more efficient—or eliminated altogether. From the initial concept through to final production, ensuring the right improvements are implemented in your die casting is crucial for <a href="/additional-capabilities/part-improvement" target="_self">creating a high-quality component</a>.Download your free copy of our Die casting design guide to learn:<ul><li>How to reduce component weight</li><li>Why wall thickness adds to cost</li><li>The best draft angle for internal versus external surfaces</li><li>The one critically important factor frequently overlooked by designers</li></ul>From the guide:“<a href="/additional-capabilities/engineering" target="_self">Design for manufacturing (DFM)</a> is a core methodology that ensures your die cast parts perform to specification and require the minimum number of secondary operations. This is important when you consider that these operations can often represent as much as 80% of the component cost.”Please complete the form to access your copy of the white paper.

Die casting mold for metal to be injected

Dynacast_Resources_Die Casting Mold

Explore design tips and considerations for producing high-quality, cost-efficient die cast parts with fewer secondary operations and improved manufacturability.

Your complete die casting design guide

Download your free copy of our Die casting design guide to learn how to reduce component costs by minimising secondary operations and optimising design for manufacturing. 

Die casting design guide

Expand your knowledge of Dynacast prototyping

Black and Dynacast blue thermal map pattern

Prototyping

Prototype to production

Spin casting

Machining from solid

Multi-metal tooling

Investment casting

Beyond the basics

Expand your knowledge of Dynacast prototyping

Article

Article

White Paper

Global reach, local expertise

Interested in starting your die casting project?