What are common aluminum alloys used in die casting?

Are Aluminum Die Castings Cost-Effective for Mass Production?

Low Per-Unit Cost at Scale

Aluminum die casting is highly economical for high-volume production due to its short cycle times and compatibility with multi-cavity tooling. Once the mold is developed, thousands of identical parts can be produced rapidly, reducing the per-unit cost significantly. For example, in automotive production, die casting reduces total cost by 20–30% compared to machining or welding multiple parts.

Tool Longevity and Process Efficiency

Die casting molds—often made from hardened tool steel—can produce over 100,000 shots before replacement, making them ideal for amortizing tooling costs across large batches. With automated injection and ejection systems, aluminum die casting services minimize labor input and ensure consistent part quality with tight tolerances (±0.01mm), reducing the need for secondary machining.

Minimal Material Waste

Aluminum die casting is a near-net-shape process, meaning parts come out of the mold close to their final dimensions. This reduces material waste and machining time. Recycled aluminum scrap is often remelted and reused in the process, cutting raw material costs and improving sustainability.

Integrated Features Reduce Assembly Costs

The ability to mold complex geometries—including bosses, holes, ribs, and inserts—directly into the part reduces the need for additional joining or fastening operations. This consolidation of functions into a single casting simplifies product assembly and logistics.

Proven Across Industries

Industries such as automotive, aerospace, consumer electronics, and e-mobility consistently adopt aluminum die casting for high-volume, cost-sensitive parts, from housings to structural supports.

Manufacturing Services for High-Efficiency Aluminum Die Casting

Neway offers end-to-end aluminum die casting solutions tailored for mass production. With in-house tool and die making, CNC finishing, and over 20 years of experience, we deliver scalable, cost-effective manufacturing with ±0.01mm precision and global fulfillment.