Dynacast FAQ

Die casting is a high-speed manufacturing process that injects molten metal under high pressure into a reusable steel die. This process is ideal for producing a high volume of complex, near-net-shape components with exceptional precision and tight tolerances.

The die casting process offers several key benefits, including:

• High-Volume Production: Our automated systems can produce hundreds of thousands of identical parts with unmatched efficiency.
• Dimensional Accuracy & Stability: We achieve industry-leading tight tolerances, eliminating the need for extensive secondary machining.
• Part Consolidation: Complex assemblies can often be designed as a single, consolidated die cast component, reducing assembly time and cost.
• Superior Surface Finish: Die cast parts are ready for a wide range of finishes with minimal preparation.

We work with zinc, aluminum, and magnesium alloys. Our engineering team can help you select the best metal for your specific application based on your needs for strength, weight, corrosion resistance, and cost.

Quality assurance in die casting is maintained through rigorous process control, from material inspection to final part verification. From our in-house machine building to our automated monitoring systems, we ensure that every part meets or exceeds specifications. Our quality management systems are certified to global standards.

Minimum wall thickness is highly dependent on the part geometry and material. For aluminum, we can achieve walls as thin as 0.3mm in some cases. Our engineers can work with you during the design phase to optimize wall thickness for strength and cost.

Die casting is capable of holding some of the tightest tolerances in the industry. For zinc, tolerances between ±0.001" and ±0.002" are possible. For aluminum die casting, we can achieve tolerances of ±0.002" to ±0.004".

We offer in-house design and engineering services to optimize your part for the die casting process. By involving engineers early, you can apply Design for Manufacturing (DFM) principles, which leads to a more efficient, cost-effective, and high-performing final component.

Die casting prototypes include a variety of methods, including 3D printing and soft tooling, to validate designs before committing to full production tooling.

Dynacast provides a wide array of secondary and finishing operations, including machining, assembly, cleaning, plating, powder coating, and more.

Yes, Dynacast offers in-house tooling and maintenance—and we even have a dedicated tooling and mold center in Germantown, WI.

Our process focuses on the "lowest total cost" rather than just the lowest part price. This includes reducing or eliminating secondary operations like machining, simplifying assembly with part consolidation, and achieving a faster time-to-market.

Typical lead time from design to first production parts varies depending on project requirements, with quality testing and design-for-manufacturability (DFM) reviews being the primary factors influencing timing. For a more accurate estimate tailored to your project, we recommend speaking directly with one of our engineers.

You can submit your project details and 3D models through our "Request a Quote" form on the website. Our team will review your requirements and provide a detailed quotation.

The Dynacast difference lies in our global scale, proprietary technology, and engineering expertise. We combine the world's most precise die casting machines with a collaborative approach to help you solve complex manufacturing challenges and deliver a superior product.