Applications

Aluminium die casting suits products where strength, heat dissipation and outdoor use come together: enclosures for lighting and electronics, heat sinks, structural parts and load-bearing components of equipment.

The casting process offers great design freedom: ribs, cooling fins and mounting points are cast in one piece. Functional faces and close fits are then finish-machined.

Finishing options include powder coating, wet painting and textured coatings, matched to the operating environment and appearance.

Modular LED fixture with cast aluminium housings for sports lighting — Die-cast aluminium LED housings · read the case

From casting design to repeat series

—Review of geometry, wall thicknesses and draft angles for casting
—Tooling coordination and trial castings at the casting partner
—CNC finish-machining of fits, threads and sealing faces
—Coating and surface treatment, matched to the operating environment
—Repeat series to fixed specifications, with delivery agreements

Before the mould investment, a machined aluminium prototype can validate the design.

Close-up of a textured black coating on a cast aluminium surface — Textured coating on cast aluminium

Designing for casting

Uniform wall thicknesses, generous draft angles and well-considered transitions prevent shrinkage cavities and warpage. Where the CAD design can be made more castable, we propose it through our Engineering & DFM review, including the consequences for the mould and cost.