How To Choose A High Pressure Die Casting Company - Blog

Popular in the manufacture of lightweight and often complex automotive and aerospace components, as well as the production of everyday consumer goods, many OEMs are on the lookout for a reliable high pressure die casting company.

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The question is, what makes a good partner for this process? What should you look out for and what should you avoid?

Let’s take a closer look…

What is high pressure die casting?

High pressure die casting is a repetitive process where identical parts are cast at high production rates, by injecting molten metal under pressure into a metal die.

The die is sprayed with cooling lubricant to regulate temperature and ease casting release, before high quality molten alloy is transferred from the furnace to the shot sleeve by automatic ladle.

Advanced real-time shot control software monitors and adjusts every aspect of the injection, cooling and ejection phases. Finally, the casting is ejected from the tool and inspected. The tool and machine are then ready to repeat the cycle.

Consider capacity.

High pressure die casting can be used to produce an extremely diverse range of parts, but the size of a manufacturer’s machine will limit the measure of the casting they can create.

If the breadth of the machinery meets your needs, you should then consider if they can keep up with the volume of orders you’re working with. Bear in mind that if you’re creating products for a fast-paced industry, this could involve a significant upsurge from your initial batch.

A supplier with the capacity to rapidly upscale production will enable you to react quickly to changes in demand. So, don’t get caught short if market forces suddenly swing in your favour – make sure you have a casting partner who can keep up with your long-term goals.

Ensure flexibility.

The high pressure die casting process requires complex machinery and tooling. For this reason, you’re likely to find that high start-up costs are often paired with long casting runs to offset the investment.

When you search for a casting partner, you’re likely to find that the majority of foundries only offer their services for high volume orders, claiming that lengthy set-ups make the process prohibitive to small quantities of zinc or aluminium die castings.

This isn’t true of everyone, however. If you’re leaning towards a shorter run, be sure to source a supplier that has optimised their tooling preparation and set-up operations to make the process more accessible to customers who require only small quantities.

MRT Castings, for example, can provide the complete service no matter how small a batch you need – so don’t be pressured into increasing your order if it’s not aligned with your requirements.

Insist on excellent quality control.

As high pressure die casting enables fast, precise and cost-effective production of aluminium and zinc components, it’s often favoured by highly innovative industries where product appearance and dimensional tolerances are critical.

If there’s no margin for error in the castings you require, you’ll need to make sure that quality control from your supplier is second to none.

Ideally, any prospective partner should be able to demonstrate that they are certified to ISO standards and can inspect your castings using both advanced machinery and highly trained professionals.

Enquire into full-service offerings.

Production cycles for even a single cast part can become complex when you need to go through numerous third parties to get the job done. Moreover, it’s likely to add to your stress as an OEM by increasing both the cost and margin for error.

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Consider a full-service partner who can quickly adapt to your needs - from the choice of alloy to tooling design and manufacture, surface finishing, mechanical assembly and even logistics.

Ready to discuss a high pressure die casting idea?

MRT Castings are experts with over 70 years’ experience in the manufacture of high-quality aluminium and zinc die castings, across a wide range of applications and industries.

In the fast-paced automotive industry, choosing the right casting suppliers and manufacturers is vital for producing high-quality components. Automotive industry professionals, including engineers, designers, and product managers, rely on the expertise and capabilities of trusted suppliers to provide top-notch casted parts.

This comprehensive guide explores the USA’s top 5 automotive casting suppliers and manufacturers. Also focuses on their specialties, track records, and why they are the preferred choice for automotive professionals seeking high-quality casting components.

Why it’s Important to Choose the Right Automotive Casting Suppliers and Manufacturers

• Choosing the right casting suppliers and manufacturers is significant in the automotive industry. Right supplier analysis and onboarding are essential to producing automotive components, impacting their quality, durability, and performance. High-quality molds contribute to critical automotive parts’ precision, strength, and reliability. Partnering with reputable suppliers ensures consistency in the manufacturing process, reduces the risk of defects, and enhances overall product quality.

• Automotive professionals understand that subpar casting molds can lead to quality defects, production delays, compromised safety standards, and increased costs. Maintaining a competitive edge in the automotive market necessitates collaboration with trusted casting suppliers and manufacturers.

Top 5 Automotive Casting Suppliers and Manufacturers in the USA

ZETWERK

Zetwerk is a leading manufacturing company that produces casting products for engineering, infrastructure, energy, automotive, and aerospace. Its highly skilled tool designers deliver custom-designed die-cast components without any hassle. Based on various parameters like annual volume, part size, weight, geometry, and surface finish, Zetwerk advises customers to select the perfect casting process.

Its array of offerings includes High Pressure Die Casting (HPDC), Low-Pressure Die Casting (LPDC) and Gravity Die Casting (GDC) for different material selections, including aluminum alloys, zinc alloys, brass, copper, and magnesium. Zetwerk’s commitment to quality assurance and rigorous production criteria is a major strength of the company.

The organization has a thorough procedure for manufacturing and supply chain to ensure unmatched customer satisfaction. This organization is able to provide its customers with dependable and high-performing goods thanks to the company’s dedication to quality. Some critical materials handled by Zetwerk are:

• Aluminum Casting
• Copper Alloy Casting
• Grey Iron Casting
• Ductile Iron casting for 200kg rail gearbox housings with Grade 1 x-ray soundness requirements
• Low-Alloy Steel Casting
• Various Alloy Casting that includes 304 and 316 stainless, high nickel alloys for power generation castings

Martinrea International

Martinrea International is a renowned automotive casting manufacturer that excels in advanced aluminum and magnesium casting solutions. Their diverse product portfolio includes powertrain, chassis, and structural components. They are experienced in light-weight low-pressure die-casting products for engines of sedan, and hypercars.

With a global presence and state-of-the-art facilities, Martinrea International is well-positioned to meet the demanding requirements of the automotive industry. Their collaborative approach and commitment to technological advancement have made them a preferred choice for automotive manufacturers seeking high-quality casting process.

Mercury Marine

Mercury Marine, part of Brunswick Corporation, is renowned for its aluminum and steel casting excellence. They offer various casting solutions for the automotive industry, including engine blocks, cylinder heads, transmission cases, and more.

Mercury Marine’s dedication to precision and performance has earned them a strong reputation in the automotive sector. They produce the most complex boat propellers made of steel, aluminum, and alloys. They leverage their extensive experience and cutting-edge manufacturing techniques to deliver high-quality casting parts.

Gibbs Die Casting Corporation

Gibbs Die Casting Corporation has a long-standing history of serving the automotive industry with its expertise in aluminum die casting. They provide comprehensive casting solutions for various automotive applications, including powertrain components, suspension systems, and structural parts.

Gibbs Die Casting Corporation’s commitment to continuous improvement and customer satisfaction has established them as a trusted partner for automotive manufacturers in the USA. They prioritize quality control measures to ensure the production of reliable and precise casting parts.

Metal Technologies Inc.

Metal Technologies Inc. is a leading supplier of complex aluminum and magnesium castings for the automotive industry. They produce high-quality casting parts for critical applications such as engines, drivelines, and structural components.

With advanced technologies and extensive expertise, Metal Technologies Inc. caters to the unique needs of automotive manufacturers. Their commitment to innovation, continuous improvement, and adherence to stringent quality standards have earned them a strong position in the market.

Tips for Selecting the Right Automotive Casting Supplier or Manufacturer

• Selecting the right automotive casting supplier or manufacturer requires careful consideration and evaluation. Assessing the supplier’s capabilities, expertise, production capacity, and technological advancements is crucial. Compatibility with specific casting needs and the ability to offer customized solutions are essential factors.

• Negotiating contracts, pricing, and terms ensure a mutually beneficial partnership. Clear communication channels and responsiveness are key to establishing effective collaboration. Automotive professionals should also emphasize the importance of ongoing feedback and continuous improvement initiatives to drive innovation and enhance product quality.

Evaluating the Performance of Automotive Casting Suppliers and Manufacturers

• Evaluating the performance of automotive casting manufacturers is crucial to ensure successful collaborations. Metrics such as quality control processes, certifications, production capacity, technological capabilities, and customer satisfaction must be assessed. Reliable suppliers maintain robust quality control processes that adhere to industry standards and consistently deliver high-quality casting molds.

• Customer satisfaction can be evaluated through references and testimonials from previous clients, showcasing their positive experiences with the supplier. By conducting thorough evaluations, automotive professionals can identify suppliers that align with their quality, capacity, and technical requirements.

Key Takeaways

In the competitive automotive industry, selecting the right casting manufacturer is paramount for delivering high-quality components. Automotive professionals can make informed decisions by considering factors such as quality, pricing, production capabilities, delivery times, and customer support.

The company is the world’s best Automotive Die Casting Solution supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

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