Pressure die casting is a high-speed manufacturing process used to produce dimensionally accurate metal components with repeatability, a clean surface finish, and efficient cycle times. It is widely used for aluminum and zinc parts in automotive, electrical, machinery, and industrial applications.
Hi-WiLL Engineering Solution LLP designs and builds the pressure die casting die, casts the aluminium component, CNC-machines it, and inspects it, all inside one ISO 9001:2015 facility. One partner. One quality system. Zero handover risk.
Since 2006, Hi-WiLL has engineered pressure die casting dies for foundries across India — using NX CAD/CAM and Delcam/PowerShape, H13 tool steel and controlled heat treatment. Today, that same tool room feeds our own casting cells.
For you, that means gating and venting designed by the people who will run the die; engineering changes turned around in days, not months; and a single accountable partner from the first DFM review to the last dispatched carton. Our 43,750 sq ft Rajkot campus puts die making, casting, CNC machining and a full NDT lab under one roof — so quality never crosses a vendor boundary.
0.05–50 kg
Per-Piece Weight Range
SS304 / SS316 / WPS
Core Material Grades
High pressure die casting (HPDC) forces molten aluminium into a reusable hardened-steel die at pressures of 700–1,200 bar. The cavity fills in milliseconds and the metal solidifies under intensification pressure — producing a dense, near-net-shape component with an excellent as-cast surface finish.
Compared with sand or gravity casting, HPDC delivers thinner walls (down to ~1.5 mm), tighter repeatable tolerances, higher production rates and dramatically less machining, which is why it dominates automotive, electrical, pump-and-valve and appliance components the world over. The trade-off is a one-time die investment, which is exactly where an in-house toolmaker becomes your cost advantage.
| Process | Cold-chamber high pressure die casting (HPDC), single & multi-cavity, family dies |
|---|---|
| Machine locking force | 120 T – 660 T |
| Casting weight | 50 g – 8 kg per shot |
| Max part envelope | ≈ 600 × 450 mm projected area, geometry dependent |
| Min wall thickness | 1.5 mm (alloy & flow-length dependent) |
| As-cast tolerance | ISO 8062 CT4 – CT6; draft 0.5° – 2° |
| Machined tolerance | Critical features to ±0.05 mm, bores to H7 on request |
| Surface finish | Ra 1.6 – 3.2 µm as-cast; finer after machining / blasting |
| Economic batch | 500 – 200,000+ pcs / year |
| Secondary operations | Trimming · shot blasting · vibro-finishing · CNC machining · tapping · leak testing · powder coating & anodising via certified partners |
| Inputs accepted | 2D drawings (PDF/DXF) · 3D CAD (STEP/IGES) · physical samples for reverse engineering |
| Alloy | Character | Typical use |
|---|---|---|
| ADC12 (Al-Si-Cu) | The general-purpose HPDC workhorse — excellent castability, good strength & machinability | Motor housings, gearbox covers, brackets, appliance bodies |
| A380 / A383 | High fluidity for thin-wall, complex geometry; good corrosion resistance | Precision housings, heat sinks, electronic enclosures |
| LM6 (Al-Si12) | Superb corrosion resistance and pressure tightness; ductile | Pump & valve bodies, marine and water-contact parts |
| LM24 | Good pressure tightness, fluidity and surface finish | General engineering castings, covers, guards |
| Zinc ZAMAK 3 / 5 ✱ | On request — thin walls, fine detail, excellent plating base | Hardware, locks, small precision components |
Your CAD is reviewed for draft, wall sections, ribs and undercuts. Gating, overflows and venting are engineered in NX CAD/CAM and Delcam/PowerShape to fill clean and eject true.
Cavities and cores are machined, heat-treated to 44–48 HRC and bench-fitted in our own tool room. First-shot tryout with a documented first article report.
Aluminium is melted and held at 640–680 °C, degassed, and spectrometer-verified against the alloy standard for every heat.
The die is lubricated and thermally conditioned to 180–220 °C — the quiet discipline behind dimensional repeatability and surface quality.
Slow shot pre-fills the sleeve, fast shot fills the cavity in milliseconds, then 700–1,200 bar intensification holds until solidification. Shot parameters logged per cycle.
Castings are ejected, cooled and trimmed of runners and flash on dedicated trim tooling — clean, consistent, ready for finishing.
Shot blasting, then machining on HAAS, FEELER & Ace Micromatic VMCs, TAL HMC, CNC turning and 4th/5th-axis centres — the same shop that machines for defence and pharma OEMs.
CMM dimensional reports, radiography for internal soundness, dye-penetrant and hardness checks — then export-grade packing to Mundra, JNPT or your dock.
A pressure die casting is only ever as good as its die. Because Hi-WiLL builds PDC dies as a core business — not a bought-in service — you gain four advantages most foundries can’t offer:
The engineers who design your runner, overflow and venting layout are the ones who will stand at the machine — so fill simulation meets shop-floor reality.
Design revisions, extra cavities or insert replacements happen in our own tool room — turned around in days, without a tooling vendor in the loop.
H13 steel, controlled heat treatment, planned maintenance and spare inserts — with die history records you can inspect. Your tooling, protected.
Porosity, flash or dimensional drift — there's no finger-pointing between toolmaker and foundry. One roof, one root-cause, one fix.
Brackets, housings, heat sinks, motor end shields, connector bodies for ICE & electric platforms.
Motor housings, terminal boxes, IP-rated enclosures, luminaire and LED heat-sink bodies.
Pressure-tight pump housings, valve bodies and covers in LM6 / ADC12 with hydro testing.
Gearbox housings, covers and guards built for dust, vibration and Indian field conditions.
Fan hubs, motor bodies, mixer-grinder and appliance housings at consumer-line volumes.
Structural and enclosure castings with full material traceability and documented NDT.
Thin-wall A380 enclosures, RF housings and heat sinks with EMI-friendly geometry.
Machine housings, guards and fittings with appropriate finishes for hygienic environments.
| Criterion | Pressure Die Casting | Investment Casting | Sand Casting |
|---|---|---|---|
| Best for | High-volume aluminium parts, thin walls, fine finish | Complex steel/SS geometry, near-net precision | Large or heavy parts, iron & steel, low volumes |
| Typical volume | 1,000 – 200,000+/yr | 50 – 20,000/yr | 1 – 5,000/yr |
| Tolerance (as-cast) | CT4 – CT6 | CT4 – CT6 | CT8 – CT12 |
| Surface finish | Ra 1.6 – 3.2 µm | Ra 3.2 – 6.3 µm | Ra 12.5 – 25 µm |
| Min wall | ~1.5 mm | ~2 mm | ~4 – 5 mm |
| Tooling cost | Higher (steel die) | Moderate (wax die) | Lowest (pattern) |
| Per-part cost at volume | Lowest | Moderate | Higher (machining) |
| Metals | Aluminium · zinc | Steel · SS · alloys | CI · SG iron · steels |
Die design, die build, casting, machining and inspection under one roof — no handover risk.
CMM, spectrometer, radiography, ultrasonic, DP and hardness testing without third-party delays.
HAAS, FEELER & TAL machining cells hold ±0.05 mm on features your assembly line depends on.
Rajkot–Gondal NH location with direct access to Mundra, Nhava Sheva (JNPT) & Sabarmati Dry Port.
Feasibility, timeline and a transparent quotation within one working day of your enquiry.
Pressure die casting injects molten aluminium into a reusable hardened-steel die at high pressure — near-net shape, fine finish, tight repeatable tolerances, high volumes. Sand casting pours metal into an expendable sand mould, suiting larger, heavier parts, ferrous metals and lower volumes. We run both (plus investment casting) and recommend the most economical route for each drawing.
Core aluminium grades are ADC12, A380/A383, LM6 and LM24, with zinc (ZAMAK 3/5) and other international equivalents on request. Every melt is verified on our in-house spectrometer before casting.
Yes. We've built pressure die casting dies since 2006 using NX CAD/CAM and Delcam/PowerShape, H13 steel and controlled heat treatment. Dies built against your order remain your tooling; we maintain, repair and store them at our facility with documented die-history records.
Typically 50 g to 8 kg per casting on cold-chamber machines from 120–660 T locking force. Share your 3D model and we'll confirm feasibility within 24 hours.
As-cast: ISO 8062 CT4–CT6 and Ra 1.6–3.2 µm. Where drawings demand more, in-house CNC machining holds critical features to ±0.05 mm or better, with bores to H7 on request.
Because the die is a one-time investment, PDC typically pays from ~500–1,000 pieces/year and improves with volume. Below that, we can often quote the same part in sand or investment casting from the same campus.
Yes — trimming, shot blasting, CNC machining, tapping, leak testing and inspection (CMM, radiography, DP, hardness) all happen under one roof, so you receive ready-to-fit, inspection-verified components.
We ship to Europe, the USA, the Middle East and Southeast Asia via Mundra, JNPT and Sabarmati Dry Port, with material certificates, dimensional reports and inspection documentation supplied on request.
Investment casting — also called lost-wax casting — is a precision process where a wax pattern is coated in a ceramic shell, the wax is melted out, and molten metal is poured into the resulting mould. It produces complex, near-net-shape parts with excellent surface finish and minimal machining allowance.
From 0.05 kg to 50 kg per piece, across SS304, SS316, and WPS grades — covering small precision components through to larger structural castings.
SS304, SS316, and WPS as standard. We also machine carbon steel, alloy steel (EN8/EN19/EN24), and non-ferrous metals elsewhere in our facility — send us your specification and we'll confirm fit for casting.
Yes. Our in-house die and pattern making division designs and builds tooling from your drawing, a 3D file, or a physical sample via reverse engineering.
Yes — our CNC machine shop (VMC, HMC, and CNC turning) is in the same facility, so finish-machining happens without shipping the casting to a separate vendor.
Dimensional verification in our in-house QC lab, dye-penetrant testing, and — where specified — spectrometric composition analysis, radiography, and ultrasonic testing through accredited partners.
Tolerances are agreed per project based on part geometry and application — investment casting's near-net-shape accuracy typically reduces the machining allowance needed versus sand casting. Share your drawing and we'll confirm what's achievable.
Lead time depends on pattern/die development, part complexity, and order volume. A provisional timeline is confirmed once we've reviewed your drawing and specification.
Yes — we coordinate export documentation and packing to customer specification, and regularly work with overseas customers by drawing, sample, and remote communication.
We support both single-piece prototype trees and full production runs. Tell us your volume and we'll advise the most practical approach for your project.
Yes — our reverse-engineering process can develop a pattern directly from a physical sample where no drawing exists.