Die Casting Service

Get dependable and production-ready die casting services for custom metal components. At XY Machining, we specialize in high-pressure die casting for aluminum and zinc alloys, delivering accurate, repeatable, and cost-effective parts for medium to high-volume manufacturing. From prototype validation to full production runs, we ensure consistent quality and fast turnaround. Our digital workflow supports secure file uploads, detailed DFM analysis, and competitive pricing. Whether you require lightweight aluminum die casting for automotive parts or durable zinc die casting for electronics housings, our engineering team ensures every project meets strict dimensional and performance standards.

Get instant pricing, project lead times, and DFM feedback.

Accepted File Types: STEP, STP, SLDPRT, STL, DXF, X_T, X_B, IPT, CATPART, PRT, SAT, 3MF, JT

Our Instant Quoting Engine is covered by U.S. Pat. Nos. 11,086,292, 11,347,201, 11,693,388, 11,698,623, 12,099,341, and 12,189,361. Other patents pending.

What is Die Casting?

Die casting is a high-pressure metal casting process where molten non-ferrous metal is injected into a hardened steel mold cavity. This method allows the rapid production of complex, high-precision metal parts with smooth surfaces and tight tolerances. It is widely used for aluminum, zinc, and magnesium components in automotive, aerospace, electronics, and industrial sectors. At XY Machining, we use advanced high-pressure die casting equipment combined with precision mold design to produce consistent and repeatable parts. Our engineers carefully review wall thickness, draft angles, and part geometry to reduce porosity, shrinkage, and flash, ensuring durable and dimensionally stable castings.

Why Choose XY Machining for Die Casting?

Our die casting services combine engineering expertise with certified quality systems to deliver reliable production results. We support aluminum and zinc die casting projects from tooling design to final machining and finishing. Every mold is developed for optimal flow control and long tooling life, ensuring efficiency across high-volume runs.
We follow strict inspection standards, including CMM inspection, visual checks, and material certification. With ISO-aligned quality management and full traceability, we help manufacturers achieve strong mechanical performance, consistent surface quality, and on-time delivery for critical applications.

As Machined

A standard finish directly from the mold with fine texture. Suitable for internal components or parts requiring secondary machining.

Bead Blasting

Creates a uniform matte surface that improves appearance and removes minor surface imperfections from cast parts.

Brushing

Applies fine linear patterns for an enhanced metallic look, commonly used for visible aluminum components.

Anodizing

Provides corrosion resistance and decorative color options for aluminum die cast parts.

Hardcoat Anodizing

Adds a thicker protective layer for wear resistance in industrial and mechanical environments.

Conductive Anodizing

Applies a durable and uniform coating that improves corrosion resistance and aesthetic appeal.

Transparent Polishing

Enhances surface smoothness for components requiring decorative or functional refinement.

Mirror Polishing

Adds protective and cosmetic finishing suitable for consumer and automotive applications.

Die Casting Surface Finishes

Design Guidelines For Die Casting

Feature	Guideline
Process Types	High-pressure aluminum and zinc die casting
General Tolerances	±0.1 mm to ±0.2 mm depending on geometry
Minimum Wall Thickness	0.8 mm (zinc), 1.0 mm (aluminum)
Maximum Part Weight	Up to 10 kg (aluminum), 5 kg (zinc)
Surface Finish	As-cast, polished, powder coated, anodized
Tooling Life	50,000 to 500,000+ shots
Production Volume	Medium to high-volume manufacturing
Secondary Operations	CNC machining, drilling, tapping, finishing
Quality Inspection	CMM inspection, visual checks, material reports

What Makes XY Machining Different from Others

Instant Smart Quoting

Upload your CAD files to receive fast, accurate pricing with design-for-manufacturing (DFM) insights.

Global Manufacturing Network

Scalable CNC milling capacity for both low-volume and production manufacturing.

Certified Quality Control

Comprehensive inspections, calibrated measuring equipment, and documented QC processes.

Fast Reliable Delivery

On-time production scheduling and dependable shipping for U.S. customers.

Our Die Casting Gallery Parts

Explore our range of custom die cast parts, showcasing precision mold design and advanced metal casting capabilities. From aluminum housings and structural covers to zinc mechanical components, each project demonstrates our focus on dimensional accuracy, surface quality, and production efficiency. We serve automotive, industrial equipment, electronics, and consumer product manufacturers with dependable aluminum and zinc die casting services built for performance and long-term reliability.

XY Machining Industries Solutions

Medical Precision

Delivering high-precision parts with zero-tolerance accuracy for the healthcare sector. We ensure every component meets the strict safety and quality standards required for medical equipment.

Electronics Industry

Manufacturing micro-accurate components for complex electronic devices and circuitry. Our process ensures superior conductivity, heat resistance, and a perfect fit for every small-scale part.

Automotive Engineering

Precision machining for high-stress engine parts and structural automotive components. We deliver durable, high-performance solutions that drive innovation in the modern automotive industry.

Robotics Solutions

We provide custom CNC machining for advanced robotic components and automation systems. Our parts are engineered for durability and high-speed performance in demanding environments.

Die Casting Materials

Our die casting services use high-quality non-ferrous alloys engineered for strength, corrosion resistance, and excellent castability. All materials are selected based on mechanical performance, thermal requirements, and cost efficiency.

Metals

Lightweight, corrosion-resistant, and ideal for structural and automotive components.
Common grades: A380, ADC12, A360, AlSi9Cu3

Excellent dimensional stability and surface finish, ideal for detailed small parts.
Common grades: Zamak 3

Zamak 5

Zamak 7

Extremely lightweight with strong strength-to-weight ratio, suitable for aerospace and electronics.

Grades

AZ91D

AM60B

Used for specialized electrical and thermal conductivity applications.

Grades

Copper-Based Die Casting Alloys

Rapid Tooling

Rapid tooling let’s you go faster to go from an idea to functional parts. With our advanced CNC machining service, we create molds and tooling with precision needed to test designs, validate fit, and function and bring products to market faster. It’s perfect for prototypes, low volume runs, and early-stage development where outworking competitors is critical and precision matters most.

Production Tooling

For our production tooling, we prioritize long-term durability. With top grade materials and precision CNC machining, we make tooling that allows full-scale production without losing accuracy. If you need thousands of the same parts, and even with batch production, we deliver consistent, reliable tooling and stable production cycles.

Pros of Die Casting

Cost-Effective Production:High-pressure die casting minimizes material waste and reduces per-part cost in large volumes.
Complex Geometries: Supports intricate shapes, thin walls, and detailed features without extensive machining.
High Strength-to-Weight Ratio: Aluminum and magnesium castings provide durability while maintaining lightweight structure.
Excellent Surface Finish: Produces smooth surfaces suitable for anodizing, powder coating, or painting.
High Production Efficiency: Enables fast cycle times and repeatable manufacturing for medium to high-volume production.

Get In Touch

From Prototype to Production — One Reliable Partner

XY Machining delivers precision CNC machining services for engineering teams that require tight tolerances, documented quality control, and dependable delivery. From prototype development to full production, we manufacture functional, production-ready components built exactly to your technical drawings. Our team combines advanced CNC milling and turning capabilities with structured inspection processes to ensure accuracy, repeatability, and consistent results — regardless of part complexity.

Proven expertise in medical, automotive, electronics, and robotics industries
Responsive engineering support with fast quotation turnaround
Modern 3-axis and 5-axis CNC machining capability
Collaborative DFM feedback to reduce risk and cost
Reliable on-demand production with documented inspection

Get In Touch With Us!

Prompt response guaranteed within 12 hours

How It Works – 3-Stages Workflow

We guarantee that CNC parts are delivered on time and that the process is completely transparent in the following 3 simple steps:

Upload Your Files

Instant prices with DFM feedback for many file types.

We Manufacture Your Parts

You can select from many materials and methods.

Tracking and Receiving Your Parts

View the QC documentation and inspection photographs.

End-to-End Solutions From XY Machining

Rapid Prototyping

With our CNC machining service, bringing your ideas is a thing of the past. We create prototypes with the functionality or you to improve your ideas with minimal to no impact on production.

Low Volume Production

High-quality production of machined parts is possible without the need for high volumes of parts. Our low-volume production service is tailored with high-volume flexibility to suit your early-stage product needs.

End-to-End Solutions

Your entire production workflow is managed by us from start to finish. Scheduled delivery is guaranteed for all projects regardless of complexity.

Frequently asked questions

What is the difference between aluminum and zinc die casting?

Aluminum die casting is ideal for lightweight structural parts, while zinc die casting offers superior detail, dimensional stability, and surface finish for smaller components.

What tolerances can you achieve in die casting?

Typical tolerances range from ±0.1 mm to ±0.2 mm depending on part size and geometry, with tighter tolerances possible through secondary CNC machining.

How long does die casting tooling last?

Tooling life typically ranges from 50,000 to over 500,000 shots depending on alloy type, mold material, and maintenance.

Is die casting suitable for low-volume production?

Die casting is most cost-effective for medium to high-volume production. For very low volumes, alternative casting or machining methods may be recommended.

What industries use die casting services?

Common industries include automotive, aerospace, electronics, industrial machinery, consumer products, and telecommunications.