Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper,aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The main die casting alloys are: zinc, aluminum, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zamak; zinc aluminium; aluminum to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium. The following is a summary of the advantages of each alloy:
  • Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.

  • Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.

  • Magnesium: the easiest metal to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.

  • Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.

Maximum weight limits for aluminum, brass, magnesium and zinc castings are approximately 70 pounds (32 kg), 10 lb. (4.5 kg), 44 lb. (20 kg), and 75 lb. (34 kg), respectively.

The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below. The thickest section should be less than 13 mm (0.5 in), but can be greater.
Metal Minimum section Minimum draft
Aluminum alloys 0.89 mm (0.035 in) 1:100 (0.6°)
Brass and bronz 1.27 mm (0.050 in) 1:80 (0.7°)
Magnesium alloys 1.27 mm (0.050 in) 1:100 (0.6°)
Zinc alloys 0.63 mm (0.025 in) 1:200 (0.3°)