Our Capabilities
High-Pressure Aluminum Die Casting – Precision, Lightweight, and Complex Parts Delivered at Scale
AOP Die Casting specializes in high-pressure aluminum die casting, delivering high-integrity, lightweight components with tight tolerances and excellent repeatability for demanding applications in EV, automotive, electronics, and industrial sectors.
The High-Pressure Aluminum Die Casting Process
Our core capability is cold-chamber high-pressure die casting (HPDC), where molten aluminum is injected into hardened steel dies at pressures up to 150 MPa. This enables rapid production of complex, thin-wall parts with superior surface finish and dimensional accuracy.
1. Die Preparation
Dies preheated and coated with release agent for optimal release and longevity.
2. Metal Injection
Molten aluminum (ADC12, A380, A360, etc.) forced into cavity in milliseconds under high pressure.
3. Solidification & Intensification
Holding pressure applied to minimize porosity and ensure dense microstructure.
4. Ejection & Trimming
Part ejected, gates/overflows trimmed automatically or manually.
Equipment & Production Capacity
- Die Casting Machines: Cold-chamber machines from 280T to 2000T clamping force
- Part Weight Range: 0.1 kg to 15 kg per shot
- Annual Capacity: Over 3000 tons of aluminum castings
- Tooling: In-house mold design, Moldflow simulation, and CNC machining for rapid prototyping and production tools
- Alloys: ADC12, A380, A360, A413, and custom high-strength/heat-treatable alloys
- Wall Thickness: As thin as 0.8–1.0 mm for lightweight designs
- Cycle Time: 20–90 seconds typical, depending on part size/complexity
- Production Volume: Ideal for medium to high-volume (10,000+ pcs/year)
Key Technical Capabilities
Precision & Tolerances
General tolerances: ±0.1–0.3 mm (ISO IT11–IT13); critical features: ±0.02 mm with post-machining
Surface Finish
As-cast: Ra 1.6–3.2 μm; suitable for powder coating, anodizing, plating without heavy machining
Structural Integrity
Low porosity via vacuum assist / intensification; X-ray / CMM validated for leak-tight & structural parts
Secondary Operations
CNC machining, drilling/tapping, vibratory finishing, powder coating, anodizing, assembly
Quality & Testing
ISO 9001; Spectrometer, CMM, air-leak test, PPAP, SPC; meet IATF 16949 expectations
Typical Applications & Industries Served
- Electric Vehicle battery trays & housings
- Automotive structural brackets & chassis parts
- Electronics heat sinks & enclosures
- Industrial equipment components
- Power tool & appliance housings
- Lighting & LED fixtures
- Telecom & 5G infrastructure parts
- Medical device housings
- Consumer electronics frames
Ready to Leverage Our Die Casting Capabilities?
From design optimization to full production, our team delivers engineering-driven aluminum solutions with speed and reliability.
Request Technical Consultation Learn About Our Expertise