High Pressure Die Casting

The decision to choose High Pressure Die Casting as a process to manufacture zinc or aluminium components is determined in the product assessment phase. 

The High Pressure Die Casting or HPDC process gets its name from how the component is created. The molten zinc or aluminium is forced into the chamber under high pressure into a securely locked die.

Next the dies are then compressed further with extremely high pressure known as (intensification pressure). Following this, the component is ejected from the machine into a holding basket. This high compression of the material expels any gas that is trapped in the molten material and feeds additional material into the cavity to compensate for any shrinkage in the metal as it solidifies. The dies are then closed to start the next cycle.

Some advantages of the HPDC process are;

  • Complex shapes reducing the number of components required in an assembly.
  • Higher production rate.
  • Integrated fastening elements.
  • Good fatigue performance.
  • Close dimensional tolerances.
  • Reduction in machining.
  • A good surface finish.
  • Thinner wall thickness.
  • Longer die life.


The HPDC process combined with either zinc or aluminium can yield a far superior product with a long component lifecycle.

These days, industries like Automotive are taking advantage of the benefits of HPDC for traditionally pressed components. A-pillars, B-pillars, C-pillars, K-frames and Suspension Components, just to name a few.   

To determine if High Pressure Die Casting is needed for your component, be sure to contact our in-house design team and they will be able to advise you from their depth of experience.

Contact us today for a Quote or to discuss your next Die Casting project.