Die casting, more accurately referred to as pressure die casting, is a metal casting process in which molten metal is forced into a mold cavity under pressure to form the desired parts. After cooling and solidification, the parts are removed and ready for finishing. At Triton, we primarily work with aluminum and zinc alloys for die casting. While other non-ferrous metals such as copper and magnesium alloys can also be used in this process, they require special treatment and are less commonly cast using die casting. In cases where production volumes are low, alternative methods like permanent mold casting or sand casting are often more suitable for these materials.

There are two primary types of pressure die casting processes: high-pressure die casting and low-pressure die casting.

• High-Pressure Die Casting operates at pressures ranging from 1,500 to 25,000 psi, depending on the size of the casting. The cycle time for this process is extremely short—typically between 30 seconds to 1 minute—resulting in high efficiency and lower per-piece costs.

• Low-Pressure Die Casting, on the other hand, uses much lower pressures, typically between 5 to 10 psi. This process has longer cycle times, ranging from 5 to 30 minutes, depending on the size of the parts. The slower, more controlled process helps achieve more uniform castings and significantly reduces porosity, making it ideal for applications requiring superior material integrity.

One consideration for die casting is its typically high upfront costs due to the expensive equipment and metal dies involved. However, Triton’s low-cost offshore suppliers offer a significant cost advantage, with tooling costs often only a quarter to half of those in the United States. Additionally, die-casting molds are a one-time lifetime charge, making the process more accessible and reducing volume requirements for our clients.

Advantages of Die Casting

Die casting offers several key benefits:

• * Exceptional surface finish and dimensional accuracy.

• * For high-pressure die casting, the lowest per-piece cost compared to other casting methods.

• * Versatility in producing complex shapes efficiently at scale.

If you’re considering die casting for your project, we invite you to share your drawings or samples with us. Our team will work closely with you to identify the optimal casting process to deliver the best quality at the lowest possible cost.