ALUYONIX Precision Die Casting
DIRECT TIER-1 / OEM DIE CASTING FOUNDRY

Precision Die Castings Engineered for Zero-Defect Serial Production.

Turnkey manufacturing partner for complex Aluminium, Zinc, and Magnesium castings. High-speed HPDC, structural LPDC, in-house tooling, and 5-axis CNC machining with strict IATF 16949 automotive compliance.

REQUEST RAPID RFQ (CAD UPLOAD)EXPLORE 6 CASTING PROCESSES
IATF 16949 / ISO 9001
24-Hour DFM Turnaround
120T – 2,500T Locking Fleet
25+
Years Foundry Engineering
ESTABLISHED EXCELLENCE
18,500+
Annual Melt Capacity
METRIC TONNES / YEAR
12M+
Precision Parts Delivered
ON-TIME: 99.2%
120T – 2,500T
Locking Force Range
MICRO-ZINC TO 2500T STRUCTURAL
ENGINEERING CAPABILITIES

Engineered Casting Processes Tailored to Your Part Geometry

From thin-wall high-speed HPDC to heat-treatable Low Pressure (LPDC) and zero-porosity Squeeze Casting, we match your production volume and stress loads to the ideal metallurgical methodology.

HPDCTOL: ±0.03

High Pressure Die Casting (HPDC)

High Pressure Die Casting forces molten aluminium or zinc under immense pressure (300 to 1,200 bar) into reusable hardened tool steel dies at speeds up to 60 m/s. It delivers near-net-shape geometry, exceptionally smooth surface finishes, and rapid cycle times.

Locking Force:120T – 2,500 Tonnes
Wall Thickness:1.2 mm – 8.0 mm
Cycle Speed:25 – 80 shots/hr
Process Specs & Applications
LPDCTOL: ±0.10

Low Pressure Die Casting (LPDC)

In Low Pressure Die Casting, molten metal is housed in an airtight furnace beneath the die. Dry air or inert gas at 0.2 to 1.5 bar smoothly pushes the melt up a ceramic riser tube into the cavity from the bottom, completely eliminating turbulent oxidation and gas entrapment.

Locking Force:Automated 4-column hydraulic rigs
Wall Thickness:3.0 mm – 30.0 mm
Cycle Speed:8 – 18 shots/hr
Process Specs & Applications
Gravity Die CastingTOL: ±0.20

Gravity Die Casting / Permanent Mould Casting

Gravity Die Casting relies solely on gravity to introduce molten metal into tiltable or static iron/steel permanent dies. Combined with sand cores, it produces intricate internal passages and deep hollow cavities impossible in HPDC.

Locking Force:Mechanical and Hydraulic Tilt Units (up to 1,500 mm platen)
Wall Thickness:3.5 mm – 45.0 mm
Cycle Speed:5 – 15 shots/hr
Process Specs & Applications
Hot & Cold ChamberTOL: ±0.02

Hot Chamber & Cold Chamber Die Casting

Selecting between Hot Chamber and Cold Chamber depends fundamentally on the melting temperature and chemical reactivity of the casting alloy. We operate both specialized lines to provide the lowest cost-per-part.

Locking Force:Zinc Hot Chamber: 30T – 250T | Al Cold Chamber: 120T – 2500T
Wall Thickness:0.6 mm (Zinc) | 1.5 mm (Aluminium)
Cycle Speed:Hot: 150 – 500 shots/hr | Cold: 30 – 90 shots/hr
Process Specs & Applications
Vacuum HPDCTOL: ±0.03

Vacuum Die Casting

Vacuum Die Casting integrates high-capacity evacuation valves that draw sub-30 mbar vacuum across the entire die cavity and shot sleeve in milliseconds just before injection. This removes 95%+ of trapped air, completely eliminating blister porosity and enabling weldability and T6 heat treatment.

Locking Force:400T – 2,500 Tonnes
Wall Thickness:1.5 mm – 10.0 mm
Cycle Speed:30 – 65 shots/hr
Process Specs & Applications
Squeeze CastingTOL: ±0.05

Squeeze Casting

Squeeze casting combines the near-net-shape geometry of die casting with the metallurgical integrity of closed-die forging. Molten metal solidifies under massive, direct hydrostatic pressure (50 to 150 MPa) applied throughout the solidification window.

Locking Force:350T – 1,800 Tonnes (Direct Squeeze Press)
Wall Thickness:4.0 mm – 50.0 mm
Cycle Speed:12 – 25 shots/hr
Process Specs & Applications
Compare All 6 Casting Methods Side-by-Side
GLOBAL OEM SECTORS

Supplying High-Integrity Castings to Critical Industries

Our components power mission-critical sub-assemblies in extreme thermal, mechanical, and vibration environments worldwide.

Automotive & EV

Battery tray enclosures, motor stator housings, inverter cases, steering knuckles, subframes.

5G & Telecom

Massive MIMO thermal chassis, RF cavity filters, high-density cooling pin fin arrays.

Industrial & Fluid

Hydraulic manifolds, compressor crankcases, heavy pump volutes, actuator housings.

Power & Electrical

Explosion-proof terminal enclosures, high-voltage switchgear casings, busbar clamps.

Consumer Hardware

Precision power tool gearboxes, lawn & garden engine blocks, premium hardware fittings.

Explore Industry Specific Case Studies
END-TO-END CAPABILITIES

From Tooling Simulation to Sub-Micron Finished Assemblies

Eliminate multi-tier vendor fragmentation. We engineer dies in-house, cast under high intensification, machine on 5-axis CNCs, and assemble ready-to-mount modules.

In-House Tooling & Simulation

MAGMASOFT flow & solidification simulation eliminates air porosity and thermal cracks before steel is cut. High-grade H13/Dievar tooling steels guarantee 100,000+ shot tool lifespan with guaranteed die maintenance.

  • MAGMASOFT Moldflow & Thermal Analysis
  • Wire EDM & Sinker EDM Tolerances < 5 µm
Tooling & DFM Workflow

Secondary CNC Precision Machining

Our climate-controlled CNC facility houses 45+ 4-axis and 5-axis Vertical Machining Centers (VMCs) and turning centers. We routinely achieve ±0.010 mm tolerances on critical bearing registers and face runouts.

  • 45+ 4-Axis & 5-Axis VMC Machining Cells
  • Renishaw On-Machine Probing Verification
CNC & Machining Capacities

Quality Assurance & Metrology

Every production lot undergoes rigorous chemical spectrometry, real-time industrial X-ray porosity grading, differential helium leak testing, and Zeiss 3D CMM automated dimensional verification.

  • Zeiss 3D CMM Inspection (0.9 µm accuracy)
  • Real-Time Digital X-Ray (ASTM E505)
Quality Equipment & PPAP
FEATURED SERIAL PRODUCTION CASE STUDY

EV Traction Motor Stator Housing

Alloy: Aluminium ADC12 / A380 • Volume: 180,000 units

The Engineering Challenge: Customer needed a complex dual-layer spiral water-cooling jacket with zero helium leak allowance (>1.5 bar) and tight cylindrical runout for direct stator shrink-fitting.

The ALUYONIX Solution: Utilized MAGMASOFT flow and thermal simulation to redesign internal chill vents and gating runner. Implemented 1,800T high-vacuum HPDC cell with automated CNC 5-axis finish milling and 100% differential pressure leak testing.

✓ Eliminated micro-porosity reject rates from 8.4% to < 0.3%. Delivered 100% helium pressure-tight parts with Cpk > 1.67.
View Filterable Case Studies Gallery
TRUSTED BY LEADING GLOBAL OEMS & TIER-1 SYSTEMS SUPPLIERS [PLACEHOLDER LOGOS]
Tier-1 Auto Systems OEM [TODO]
EV Powertrain Pioneer [TODO]
Global 5G Telecom Giant [TODO]
Hydraulics & Heavy Equip [TODO]
Power Tool Brand [TODO]
Switchgear Manufacturer [TODO]
RAPID 3D CAD QUOTATION PORTAL

Have 3D CAD Data Ready? Get DFM Feedback in 24 Hours.

Upload your STEP or PDF engineering drawing. Our tooling specialists will evaluate draft angles, parting line placement, gate design, and deliver a competitive volume quotation.

LAUNCH QUOTE ENGINECONTACT APPLICATION SPECIALIST