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Custom Die Casting Solutions for Volume Production

Karry Precision provides aluminum and zinc alloy die casting services for housings, brackets, structural components, heat-dissipation parts, and other complex metal products. From tooling development and trial casting to secondary machining and finishing, we support efficient production with stable dimensions and consistent part quality.

Integrated die design, manufacturing, and trial production
T5 and T6 heat treatment options for selected aluminum alloys
Anodizing, powder coating, painting, plating, and polishing support
Suitable for prototypes, low-volume validation, and mass production

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High-precision die casting for metal parts

Efficient production with minimal material waste

Die Casting Processes

Aluminum Die Casting

Injects molten aluminum alloy under high pressure

Produces lightweight and strong components

Ideal for housings, brackets, and heat sinks

Zinc Die Casting

Fills complex mold cavities with excellent accuracy

Creates thin walls and detailed surface features

Suitable for connectors, hardware, and small precision parts

Magnesium Die Casting

Forms lightweight magnesium alloy at high pressure

Provides a high strength-to-weight ratio

Ideal for automotive, electronic, and structural components

Case Studies

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Tolerances for Die Casting

Tolerance Level	Application	Tolerance Range
General Tolerances	Standard die-cast parts	±0.1mm to ±0.5mm
High Precision	Small, intricate parts (e.g., aerospace)	±0.1mm to ±0.3mm
Large Parts	Larger castings (e.g., automotive parts)	±1.0mm to ±2.0mm
Thin-Walled Parts	Thin-walled castings	±0.2mm to ±0.5mm
Material-Specific	Varies by material (e.g., aluminum, zinc)	±0.1mm to ±0.5mm

Not sure about the right tolerance for your part?

Our engineering team can help optimize your design.

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Available Materials for Die Casting

. Metal .
- ADC12 Aluminum Alloy
  ADC12 provides good fluidity, dimensional stability, corrosion resistance, and machinability. It is widely used for complex components requiring thin walls and detailed features.
  Key Properties:
  
  Good castability
  
  lightweight
  
  corrosion-resistant
  
  easy to machine
  Cost Efficiency:
- A380 Aluminum Alloy
  A380 offers a practical balance of strength, casting performance, pressure tightness, and surface-finishing capability. It is suitable for medium- and high-volume production.
  Key Properties:
  
  Good strength
  
  stable dimensions
  
  reliable castability
  Cost Efficiency:
- A360 Aluminum Alloy
  A360 provides improved corrosion resistance and good mechanical performance. It is suitable for components exposed to moisture, heat, and demanding operating environments.
  Key Properties:
  
  good strength
  
  heat resistance
  
  High corrosion resistance
  Cost Efficiency:
- Zamak 3 Zinc Alloy
  Zamak 3 offers excellent dimensional stability, smooth surface quality, and the ability to reproduce fine details. It is commonly used for small and precision die-cast parts.
  Key Properties:
  
  accurate details
  
  good stability
  
  easy plating
  Cost Efficiency:
- Zamak 5 Zinc Alloy
  Zamak 5 provides greater strength and hardness than Zamak 3 while maintaining good casting performance. It is suitable for parts exposed to higher mechanical loads.
  Key Properties:
  
  Higher strength
  
  good wear resistance
  
  detailed casting
  Cost Efficiency:
- Zamak 12 Zinc Alloy
  Zamak 12 provides higher strength, hardness, and wear resistance compared with standard Zamak alloys. It is suitable for structural die-cast parts requiring good mechanical performance, dimensional accuracy, and long-term durability.
  Key Properties:
  
  High strength and hardness
  
  Excellent wear resistance
  
  Good dimensional stability
  Cost Efficiency:
- AZ91D Magnesium Alloy
  
  AZ91D is a lightweight magnesium alloy with good castability, strength, and dimensional stability. It is suitable for applications where weight reduction is a major design requirement.
  
  Key Properties:
  
  Cost Efficiency:
. Plastic .
- ABS
  
  ABS offers good impact resistance, dimensional stability, surface quality, and processing performance. It is widely used for functional and cosmetic components.
  
  Cost Efficiency:
- Polycarbonate
  
  Polycarbonate provides excellent impact strength, heat resistance, and dimensional stability. Transparent and flame-retardant grades are also available.
  
  Cost Efficiency:
- Nylon (PA)
  
  Nylon offers good mechanical strength, wear resistance, fatigue resistance, and low-friction performance. Reinforced grades can provide increased rigidity.
  
  Cost Efficiency:
- POM
  
  POM provides high rigidity, low friction, excellent dimensional stability, and good resistance to repeated movement.
  
  Cost Efficiency:
- Polypropylene
  
  Polypropylene is lightweight, chemically resistant, and suitable for components requiring flexibility or repeated bending.
  
  Cost Efficiency:

Don’t See the Material You Need?

Explore our full material list or contact our engineering team for recommendations.

View Full Material Guide

Surface Finishing Options

We specialize in die casting to create complex, high-precision metal parts. Our process ensures strong, durable components with smooth surfaces, ideal for high-volume production and demanding applications.

Sandblasting

Sandblasting uses high-speed abrasive media to remove oxidation, surface residue, and minor defects while creating a clean, uniform matte texture.
Anodizing

Anodizing creates a controlled oxide layer on aluminum surfaces, improving corrosion resistance, surface hardness, and appearance. Clear, black, and custom colors may be available.
Electroplating

Electroplating deposits a metallic coating onto the component surface to enhance corrosion protection, wear resistance, electrical conductivity, or decorative appearance.
Powder Coating

Powder coating applies a dry powder electrostatically before heat curing it into a durable protective layer. It provides good resistance to corrosion, impact, scratches, and outdoor exposure.
Painting

Wet painting provides flexible color, gloss, texture, and protective options. Primers and topcoats can be selected according to indoor, outdoor, cosmetic, or functional requirements.
Chrome Plating

Chrome plating creates a bright or satin metallic appearance while improving surface hardness, wear resistance, and corrosion protection.

Sandblasting

Sandblasting uses high-speed abrasive media to remove oxidation, surface residue, and minor defects while creating a clean, uniform matte texture.

Anodizing

Anodizing creates a controlled oxide layer on aluminum surfaces, improving corrosion resistance, surface hardness, and appearance. Clear, black, and custom colors may be available.

Electroplating

Electroplating deposits a metallic coating onto the component surface to enhance corrosion protection, wear resistance, electrical conductivity, or decorative appearance.

Powder Coating

Powder coating applies a dry powder electrostatically before heat curing it into a durable protective layer. It provides good resistance to corrosion, impact, scratches, and outdoor exposure.

Painting

Wet painting provides flexible color, gloss, texture, and protective options. Primers and topcoats can be selected according to indoor, outdoor, cosmetic, or functional requirements.

Chrome Plating

Chrome plating creates a bright or satin metallic appearance while improving surface hardness, wear resistance, and corrosion protection.

*Not sure which finish is right for your part? Explore our complete guide

Common Die Casting Questions

What die casting materials does Karry Precision support?

What types of parts are suitable for die casting?

What tolerances can die casting achieve?

Can die-cast parts receive secondary machining?

What surface finishes are available?

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Ready to Start Your Custom Parts Project?

Upload your drawings (STEP, STP, IGES, STL) or contact our team for a fast and confidential quotation.