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

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

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Die cast tooling

Speak to an engineer

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

Employees discussing how a die cast tool opperates

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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 cast 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 cast tooling solutions are designed to be adaptable and custom 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 cast tooling

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

Conventional die cast 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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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 start up to re-cool the air and contents inside--impacting 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?&nbsp;<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>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 its 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.&nbsp;<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>The appliance company’s marketing team was interested in offering a swinging “milk shelf” to allow easy access to the common household staple. Connection of the milk shelf to the interior body of the refrigerator would happen via a hinge component. In order to withstand the weight of a gallon of liquid, engineers determined 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.&nbsp;<img asset_uid="bltbcfda9c92a3fe4c1" src="https://azure-na-images.contentstack.com/v3/assets/bltc3d459c709c6e7a5/bltbcfda9c92a3fe4c1/670692c5a75c9286890a2b64/Picture19.jpg" alt="Picture19.jpg" height="auto"/>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 rigidity and strength required. Dynacast Elgin designed and manufactured three parts in total: a decorative aluminium die-cast shelf and two Multi-Slide zinc hinge components.<h2>Dynacast delivers</h2>Dynacast strives to ensure every customer receives insight and expertise that adds value at every stage of the design and die cast manufacturing process. It’s why today, across multiple industries and multiple geographies, Dynacast is the name synonymous with precision-engineered metal components. Their extensive knowledge of metal die casting and reliable reputation made them a valuable partner for the appliance manufacturer.

Metal refrigerator with die cast metal cooling parts

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Discover how aluminium die casting enhances energy efficiency, while maintaining the strength and performance needed for innovative refrigerator designs.

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

<a href="/metals/aluminum" target="_self">Aluminium die castings</a> are often a top choice due to their corrosion resistance, strength, and thermal conductivity. But the castability of zinc, its thin-walled capabilities, and structural integrity make it the perfect alternative to aluminium in certain applications. Because of zinc’s greater fluidity, die castings can be made thinner, more intricate, and more complex, eliminating the need for secondary operations that are almost always necessary with aluminium. With less material being used in thin-wall applications, parts automatically become lighter, creating savings in material cost and energy. To learn more about <a href="/metals/zinc" target="_self">zinc die casting</a>, download our free webinar Zone in on Zinc: The alternative to aluminium. In this webinar, Max Gondek and Adam Scichitano of Dynacast will cover the following benefits of die casting in zinc: <ul><li>Tighter tolerances </li><li>Faster cycle times </li><li>Lower cost </li><li>Longer tool life </li><li>Medical case studies </li><li>Telecommunications/5G applications  </li><li>And more! </li></ul>Fill out the form to access our free webinar!

Telecommunications tower with aluminum parts

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Compare zinc and aluminium for die casting. Learn when zinc is the better choice for strength, detail, and cost-efficiency.

Zinc vs. Aluminium Die Casting | Dynacast

Discover why zinc die casting can be a superior alternative to aluminium for thin-walled, intricate parts in our free webinar. 

Zone in on Zinc: The Die Casting Alternative to Aluminium

<h2>Overview</h2>Are you facing quality inconsistencies, capacity constraints, or supply chain risks with your current die casting tooling? Whether you need to transition away from a distressed supplier, bring production closer to your European operations, or optimise your total cost of ownership, transferring existing tooling can feel complex.Join Dynacast Europe’s live webinar to learn how we remove the risk and simplify the process for you. We will share practical, step-by-step strategies for successful tool relocation, ensuring supply chain security without costly production downtime.<h3>In this webinar, you’ll discover:</h3><ul><li>Streamlined Processes: How to transfer existing die casting tooling for maximum efficiency and minimal disruption</li><li>Onshoring &amp; Vendor Consolidation: Strategic best practices for moving tooling closer to home within the European market</li><li>Risk Mitigation: Dynacast’s engineering framework for ensuring tool validation, tolerance protection, and seamless supply chain handovers</li><li>Regional Success Stories: Real-world case studies showcasing successful tooling transfers handled by our European facilities</li></ul>Event Details:<ul><li>Date: September 17, 2026</li><li>Time: 9:00 AM EST (3:00 PM CET)</li></ul>&nbsp;

Shipping port for manufacturing production logistics

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Discover how to safely transfer die casting tooling with minimal risk. Join Dynacast Europe's July 23 webinar and learn practical insights from real case studies.

Die Casting Tooling Transfers in Europe | Dynacast Webinar

Mitigating Risk: Die Casting Tooling Transfers in Europe

Elevate your knowledge about 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 within 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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<h2>Explore the benefits of die casting</h2>Are you new to precision die casting or an experienced professional? Staying up to date with precision die casting is essential. Learn why die casting is often more cost-efficient than other manufacturing processes, offering not only savings on part prices, but also major reductions in overall production costs! With die casting, you can produce complex net-shape parts, including intricate internal and external features with minimal draft angles, minimising secondary operations. This webinar guides our customers on how to take advantage of the benefits of die casting.Join the Dynacast Europe team as they present Explore the benefits of die casting. In this webinar, our team will cover:<ul><li><a href="/die-casting-technologies" target="_self">Die casting technologies</a></li><li><a href="/metals" target="_self">Die cast metals</a></li><li><a href="/additional-capabilities/engineering" target="_self">Design capabilities</a></li><li><a href="/resources?type=caseStudies" target="_self">Case studies</a></li><li>And more!</li></ul>Die casting explainedWhen: On demandWhere: Online – join from anywhere!Presenters: Christian Flich, Sergio Perino, Bernd Froehlich** Webinar is presented in English.**Complete the form to watch our free webinar on demand.&nbsp;

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Explore die casting fundamentals—from material flow and die filling to cooling and ejection—in this clear, beginner-friendly overview of the process in detail.

Die casting process explained | Dynacast

Explore the cost efficiency and design flexibility of precision die casting with Dynacast Europe’s expert team in our on-demand webinar 

Die casting explained

Dynacast, a Form Technologies Company, is a global manufacturer of precision-engineered metal components. Using proprietary die casting technologies, we provide robust solutions for many industries, including automotive, consumer electronics and healthcare. 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 facilities in 16 countries and consistently delivers value through engineering expertise, efficient operations and Advanced Quality Planning systems.Join us for the first instalment of the Dynacast Metal Solutions Webinar Series - Europe. In this webinar, our team will cover:<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 die casting innovations</a></li><li><a href="/resources?type=caseStudies" target="_self">Case studies</a></li><li>And more!</li></ul>&nbsp;

Manufacturing employee operating equipment in Peterborough

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

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 of expertise to deliver leading insights and case studies. 

An introduction to precision die casting

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.

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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

Safety-critical tooling transfer

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Global locations

Use our location finder to see which of our global facilities offers the processes and materials you need.

Global reach, local expertise

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Optimise design, precision, and efficiency with our comprehensive solutions.

Our engineers work closely with you from start to finish

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

Die cast tooling

Tooling solutions for every project

Multi-Slide die cast tooling

Conventional die cast tooling

Design for manufacturing

Machine building

Beyond the basics

Elevate your knowledge about Dynacast tooling

Case Study

Webinar

Webinar

CASE STUDY

Safety-critical tooling transfer

Global reach, local expertise

Explore other capabilities

Engineering

Prototyping

Part improvement

Interested in starting your die casting project?