Cast Aluminum with Thin Walls 

When considering aluminum die casting, it is often associated with large components requiring relatively thick wall sections. Advances in casting technology now make it possible to produce aluminum 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 aluminum die casting due to the need for thicker wall sections (typically 1.5 mm – 2.0 mm), which resulted in heavier parts.

A common question in die casting is: Why is it difficult to cast aluminum with thin walls? Aluminum is relatively high melting and freezing points 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 gating design, overflow placement and design, and targeted thermal management to ensure optimal outcomes.

Not interested in aluminum? Try our dynamic metal selector tool to compare mechanical and physical properties of other alloys.

Evolution of The Thin-Walled Aluminum Technology

Historically, in order to cast aluminum 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 tool design, and machine enhancements, we fundamentally changed the die casting industry forever.  

Benefits of Thin-Walled Aluminum Die Casting

One of the most significant benefits of thin-walled aluminum die casting is the ability to produce lighter components while also enabling a wider range of surface finishing options compared to other die cast 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 automotive component or handheld electronic devices. In addition, aluminum can withstand the highest operating temperatures of all die cast alloys. Cast aluminum 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.