Die casting is a manufacturing process that involves injecting molten metal under high pressure into a precision metal mold cavity, where it cools and solidifies into a desired shape. Die casting is widely used to produce complex and high-quality metal parts for various industries, such as automotive, medical, consumer electronics, aerospace, and more.

According to a report by Grand View Research, the global die casting market size was valued at USD 75.1 billion in 2020 and is expected to grow at a compound annual growth rate (CAGR) of 8.6% from 2021 to 20281. The increasing demand for lightweight, durable, and energy-efficient metal components is driving the growth of the die casting market. Die casting offers several advantages over other manufacturing methods, such as high production speed, low material waste, high dimensional accuracy, and excellent surface finish.

The most common metals used for die casting are aluminum, zinc, and magnesium. Aluminum accounts for about 80% of the die cast parts produced worldwide, due to its low cost, high strength-to-weight ratio, good corrosion resistance, and recyclability. Zinc is also widely used for die casting, especially for small and intricate parts that require high precision and durability. Magnesium is the lightest of all metals and has a high strength-to-weight ratio, making it ideal for applications that require weight reduction and fuel efficiency.

Die casting can be classified into two main types: low-pressure die casting and high-pressure die casting. Low-pressure die casting uses a ladle to pour molten metal into the mold cavity through a riser tube. This method is suitable for large and thin-walled parts that require less internal pressure and minimal porosity. High-pressure die casting uses a plunger to inject molten metal into the mold cavity at high speed and pressure. This method is suitable for small and complex parts that require high internal pressure and density.

Die casting is a versatile and reliable manufacturing process that can produce high-quality metal parts for various applications. However, die casting also has some limitations and challenges, such as high initial investment, tool wear, thermal stress, gas porosity, and environmental impact. To overcome these challenges, die casting companies are adopting new technologies and innovations, such as squeeze casting, semi-solid metal casting, vacuum die casting, hot-chamber die casting, and multi-slide die casting3. These technologies aim to improve the quality, efficiency, and sustainability of die casting products.

Die casting parts are expected to have a bright future in the global market, as they offer superior performance, functionality, and aesthetics to meet the diverse needs of customers. Die casting companies are also striving to provide customized solutions and value-added services to enhance customer satisfaction and loyalty. Die casting parts are not only metal products but also art pieces that reflect the creativity and craftsmanship of the die casters.