Hot Chamber Casting Services

Frigate offers hot chamber casting services for industrial components. This manufacturing method’s flexible component design, diverse material options, and efficient production processes make it a top choice globally. 

Our Clients

Advantages of Hot Chamber Casting Services

Faster Production Cycle

The metal melts right inside the machine's furnace pot during this process. It doesn't need to be melted in a separate pot. This means the liquid metal gets to the mold faster, speeding up the production cycle.

Dimensional Accuracy

Hot chamber casting creates durable and dimensionally stable parts that maintain close tolerance and resist heat. Additionally, they are built to resist heat effectively, making them reliable even in challenging conditions.

Less Defects and Wastage

Choose a casting technique that not only saves money but also minimizes wastage. The quick transfer of liquid metal helps achieve this. This process also lowers the risk of defects like blisters and porosity in the final parts.

Longer Die Life

Hot chamber cast parts are stronger than plastic injection moldings of the same size. Thin wall castings are both stronger and lighter than those made by other casting methods. It doesn't have separate parts welded or fastened together, so their strength comes from the alloy, not the joining process.

Superior Hot Chamber Casting Services at Frigate

Hot chamber die casting technique is perfect for easy mass production. Parts are made in a die-casting mold with little machining, allowing thousands of identical castings to be produced quickly. Components cast using hot chamber casting method offer superior dimensional accuracy, stability, heat resistance, and durability. These parts are more vital than injection-molded ones of the same size, especially for thin-walled castings. 

hot chamber casting services

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Our Hot Chamber Die Casting Process

Preparation

The process starts by preparing the die. It's made of strong steel to withstand high temperatures.

Melting

Metal is melted in a hot chamber furnace. This chamber keeps the metal molten and ready for casting. 

Injection

After that, molten metal is injected into the die under high pressure to ensure it fills every part of the mold. 

Cooling

The metal cools and solidifies quickly inside the die. This forms the shape of the component. 

Ejection

Once cooled, the die opens, and the cast part is ejected. 

Finishing

The part is inspected for quality. Any extra material is trimmed away, and the surface is finished as needed.

Post Processing Services in Hot Chamber Casting

Hot chamber casting produces high-precision components, but post-processing is essential to enhance quality, durability, and functionality. Various finishing techniques improve surface smoothness, dimensional accuracy, and corrosion resistance. Below is a detailed table of post-processing services, their technical parameters, and industry applications. 

Trimming
Shearing force: 50-500 kN
Accuracy: ±0.2mm

Automotive (small zinc components), Electronics (housings) 

Deburring
Burr size: 0.1mm - 0.5mm
Methods: Mechanical, Thermal, Chemical

Consumer Goods (handles, locks), Aerospace (small fittings) 

CNC Machining
Tolerance: ±0.01mm
Surface Roughness: Ra 0.4 - 1.6 µm
Spindle Speed: 10,000-30,000 RPM

Medical (device enclosures), Automotive (gear housings) 

Drilling & Tapping
Hole diameter: 0.5mm - 50mm
Thread depth: up to 3xD

Electronics (fasteners), Industrial (fittings) 

Grinding
Surface finish: Ra 0.2 - 0.8 µm
Material removal: 0.05-0.5mm

Aerospace (precision parts), Defense (weapon components) 

Polishing
Surface Roughness: Ra 0.1 - 0.4 µm
Methods: Manual, Robotic, Electro-polishing

Jewelry (decorative parts), Industrial (connectors) 

Sandblasting
Grit size: 50-150 µm
Pressure: 4-7 bar

Automotive (engine covers), Aerospace (aircraft fittings) 

Vibratory Finishing
Media size: 3mm - 15mm
Cycle time: 15-120 min

Consumer Goods (appliance handles), Aerospace (small parts) 

Coating & Plating
Thickness: 5-50 µm
Materials: Ni, Cr, Zn, Powder Coating, Electroplating

Electronics (switch components), Automotive (brackets) 

Heat Treatment
Temperature: 150°C - 250°C
Duration: 30-120 min, Stress Relieving

Aerospace (lightweight fittings), Defense (trigger components) 

Painting & Anodizing
Coating Thickness: 10-50 µm
Methods: Electrostatic, Spray

Consumer Electronics (covers), Automotive (trim parts) 

Powder Coating
Layer thickness: 50-150 µm
Cure temperature: 160-220°C

Industrial (frames, brackets), Medical (equipment enclosures) 

Assembly
Tolerance: ±0.05mm
Fastening: Screws, Adhesives, Press-Fit

Electronics (sensor enclosures), Industrial (tool housings) 

Leak Testing
Pressure: 0.1 - 1 MPa
Methods: Air, Helium, Water Submersion

Automotive (fuel system parts), Aerospace (valves, fittings) 

Ultrasonic Cleaning
Frequency: 20-40 kHz
Cleaning time: 5-30 min

Medical (surgical instruments), Electronics (precision parts) 

Methoding in Hot Chamber Casting

Injection Pressure
7 - 35 MPa

Automotive (gear housings), Aerospace (sensor brackets) 

Gate Velocity
30 - 60 m/s

Electronics (micro-housings), Medical (surgical tool casings) 

Plunger Speed
0.2 - 5 m/s

Industrial (hydraulic fittings), Consumer Goods (decorative components) 

Fill Time
5 - 50 ms

Automotive (small brackets), Aerospace (lightweight fittings) 

Overflows & Vents
2 - 5 % of shot weight

Defense (precision weapon parts), Electronics (connector casings) 

Sprue Diameter
4 - 12 mm

Telecommunications (RF shielding), Aerospace (fuel system parts) 

Thermal Gradient Control
5 - 50 °C/cm

Medical (implant components), Industrial (valve bodies) 

Cooling Rate
100 - 500 °C/s

Automotive (heat-resistant parts), Marine (corrosion-proof casings) 

Solidification Time
0.5 - 10 sec

Electronics (precision mounts), Renewable Energy (solar panel brackets) 

Shrinkage Allowance
0.5 - 1.5 %

Aerospace (lightweight panels), Defense (firearm components) 

Parting Line Placement
0.1 - 1 mm offset

Industrial (pump housings), Consumer Goods (high-detail castings) 

Die Temperature Control
180 - 300 °C

Aerospace (critical fittings), Electronics (heat dissipation parts) 

Runner Width
3 - 10 mm

Robotics (motor housings), Home Automation (IoT device enclosures) 

Runner Length
20 - 100 mm

Telecommunications (RF shielding), Automotive (engine mounts) 

Vacuum Assist Pressure
50 - 200 mbar

Automotive (high-precision engine parts), Medical (diagnostic tools) 

hot chamber casting services

Hot Chamber Casting Materials

We use a range of materials, including zinc, aluminum, magnesium, and lead. Each material brings specific advantages to the casting process, ensuring optimal application performance. 

Zinc Alloys

Zinc alloys are commonly used in hot chamber casting. They have excellent fluidity and high strength. Zinc parts are found in automotive components, electrical fittings, and consumer products. 

Aluminum Alloys

Aluminum alloys are also popular in hot chamber casting. It offers a good balance of strength, weight, and corrosion resistance. These alloys are used in the automotive, aerospace, and electronics industries. 

Magnesium Alloys

Magnesium alloys have lightweight properties and a high strength-to-weight ratio. They are often selected for applications requiring weight reduction, such as aerospace and automotive parts. 

Lead Alloys

Lead alloys can be used in hot chamber casting for high-density and malleability applications. They are often used in specialized industries, such as radiation shielding and some types of weights and counterweights. 

 

Customized Hot Chamber Die Casting with Frigate

Get your customized components using the hot chamber die casting method. You can benefit from various dimensions, tolerances, and surface options, ensuring that each part meets your specifications for texture and finish. Whether you need precise dimensions or specific surface treatments, we can deliver. 

We aim to provide high-quality, tailored solutions that fit your project requirements perfectly. Trust Frigate for reliable and flexible hot chamber casting services. 

hot chamber casting services

Compliance for Hot Chamber Casting Services

Frigate’s hot chamber casting services are built on strict adherence to global compliance standards. Certified protocols govern every process step to ensure precision, safety, and reliability. Our operations comply with technical benchmarks across diverse industries, from material selection to final inspections. Below is a detailed list of certifications and compliance measures: 

Key Compliance Standards and Certifications

ISO 9001:2015

Ensures robust quality management systems for consistent and superior production standards. 

IATF 16949

Specifies requirements for quality systems in the automotive industry, ensuring defect-free manufacturing. 

ISO 14001:2015

Governs environmental management systems to minimize ecological impact during casting processes. 

RoHS Directive 2011/65/EU

Restricts the use of hazardous substances in casting materials and components. 

REACH Regulation (EC) No. 1907/2006

Guarantees compliance with chemical safety standards across the supply chain. 

ISO 45001:2018

Focuses on occupational health and safety management, reducing risks in casting environments. 

NADCAP Certification

Meets aerospace-specific standards for material processing and precision casting. 

AS9100 Rev D

Sets quality management standards for the aerospace and defense sectors, ensuring reliability under critical conditions. 

Tonnage / Capacity in Hot Chamber Casting

Hot chamber casting machines are designed for high-speed production of small to medium-sized metal components. Their tonnage capacity determines the maximum clamping force, injection pressure, and shot weight, directly impacting the casting quality and material flow. Below is a table outlining key tonnage and capacity parameters with industry-specific applications. 

Clamping Force
50 - 9000+ tons

Determines mold locking capability (Die casting, Injection molding) 

Shot Weight
10g - 100+ kg

Defines max metal volume per cycle (Automotive, Aerospace) 

Mold Size
100 mm - 5000 mm

Limits casting dimensions (Small electronics to heavy machinery) 

Injection Pressure
500 - 3000 bar

Affects material flow & porosity (Thin-wall castings, Complex geometries) 

Cycle Time
30 sec - 10 min

Impacts production speed (High-volume manufacturing) 

Cooling Rate
1°C/s - 50°C/s

Influences microstructure & mechanical properties 

Casting Weight Capacity
100g - 5000 kg

Determines max component weight (Small brackets to ship propellers) 

Ejection Force
10 - 1000 kN

Required to remove casting from the mold (Thin-wall parts, Large castings) 

Material Compatibility
Aluminum, Zinc, Steel, Magnesium, Brass, Titanium

Defines application across industries (Automotive, Aerospace, Medical) 

Dimensional Accuracy
±0.01 mm - ±1 mm

Affects post-processing requirements (Precision parts vs. heavy castings) 

Surface Finish Quality
Ra 0.2 - 25 µm

Impacts aesthetic & functional properties (Polished vs. rough cast) 

Dimensions in Hot Chamber Casting

Hot chamber casting is ideal for producing small to medium-sized components with high precision. The dimensional capabilities of the process impact part complexity, tolerance levels, and production efficiency. Below is a high-level table outlining key dimensional parameters along with industry applications. 

Maximum Part Size
Up to 300mm (varies by alloy & machine size)

Automotive (small brackets, covers), Electronics (sensor casings) 

Wall Thickness
0.3mm - 5mm

Aerospace (lightweight fittings), Medical (precision enclosures) 

Feature Resolution
±0.02mm - ±0.2mm

Electronics (connectors), Automotive (gear housings) 

Draft Angle
0.5° - 3° (depends on alloy & complexity)

Consumer Goods (decorative elements), Aerospace (small cast parts) 

Flatness Tolerance
0.05mm - 0.5mm over 100mm surface

Industrial (machinery casings), Defense (trigger components) 

Roundness Tolerance
0.02mm - 0.1mm for circular parts

Automotive (bushings, sleeves), Medical (surgical tools) 

Corner Radii
0.2mm - 3mm

Electronics (heat sinks), Industrial (valve components) 

Shrinkage Allowance
0.5% - 1.5% (depends on alloy & cooling rate)

Aerospace (structural parts), Defense (small precision parts) 

Hole Diameter
0.5mm - 50mm

Automotive (fasteners, fittings), Medical (implants) 

Thread Size
M2 - M12

Electronics (mounting hardware), Consumer Goods (handles) 

Undercut Features
Up to 2mm depth with slides/core pulls

Aerospace (complex brackets), Automotive (internal channels) 

Aspect Ratio
Up to 10:1 for thin-wall designs

Electronics (heat dissipation parts), Automotive (lightweight covers) 

Mold Parting Line Offset
±0.1mm - ±0.5mm

Defense (precision weapon parts), Consumer Goods (high-detail components) 

Cored Hole Depth
Up to 5x diameter

Industrial (hydraulic components), Medical (fluidic devices) 

Minimum Rib Thickness
0.5mm - 2mm

Automotive (reinforced structures), Aerospace (lightweight panels) 

hot chamber casting services

Tolerance for Hot Chamber Casting Services

Dimensional Accuracy
± 0.01 mm to ± 0.05 mm

Ensures tight tolerance for part dimensions, essential for precision in assembly. 

Wall Thickness Uniformity
± 0.2 mm to ± 1.0 mm

Controls wall thickness to ensure uniformity across the entire casting, crucial for strength and thermal performance. 

Surface Finish (Ra)
Ra 0.8 to Ra 3.2

Achieves desired surface smoothness, ensuring aesthetic quality and functional wear resistance. 

Casting Porosity
< 1%

Minimizes porosity to prevent weakening of the material, ensuring structural integrity. 

Shrinkage
± 0.5% to ± 1.5%

Accounts for material shrinkage during cooling, maintaining precise part size. 

Weight Tolerance
± 0.5% to ± 2.0%

Ensures weight consistency for mechanical performance, critical in aerospace and automotive components. 

Hole Diameter
± 0.05 mm

Provides precise hole dimensions for fittings and assembly compatibility, critical for accurate assembly and function. 

Core Shift
± 0.05 mm to ± 0.1 mm

Manages core shift during casting to ensure part alignment and functionality. 

Casting Surface Hardness
50-70 HRC

Ensures proper hardness for durability, especially for wear-resistant applications. 

Tolerance on Parting Line
± 0.1 mm

Ensures the accuracy of parting lines for ease of separation and post-processing. 

Thickness Deviation
± 0.1 mm to ± 0.5 mm

Maintains consistency in thickness across the casting to optimize material properties and load-bearing capabilities. 

Microstructure (Grain Size)
ASTM E112 (Fine to coarse)

Controls the grain structure for desired mechanical properties like tensile strength and fatigue resistance. 

Sectional Variation
± 0.1 mm to ± 0.3 mm

Ensures uniformity in varying sections of the part, critical for consistent performance under load. 

Flatness
± 0.1 mm

Controls the flatness of the casting to ensure dimensional accuracy and proper fit during assembly. 

Casting Tolerance for Thin Sections
± 0.2 mm

Ensures accuracy in the thinner sections of cast parts, which can be challenging due to cooling rates and material flow. 

hot chamber casting services

Quality Testing Standards for Hot Chamber Casting Services

Dimensional Tolerances
Laser Scanning

Measures the part geometry using laser technology to ensure accurate dimension tolerances across all surfaces. 

Impact Toughness
Charpy Impact Test (ASTM E23)

Assesses the material's resistance to sudden impact, ensuring the casting can withstand mechanical shocks. 

Thermal Conductivity
Thermal Conductivity Test

Measures the casting's ability to conduct heat, ensuring proper performance in thermal applications. 

Fatigue Strength
Rotating Bending Fatigue Test

Evaluates the material’s ability to withstand repeated stress cycles without failure, critical for automotive and aerospace parts. 

Creep Resistance
Creep Testing (ASTM E139)

Measures the material's resistance to deformation under constant load at elevated temperatures, crucial for high-temperature applications. 

Elongation at Break
Tensile Testing (ASTM E8)

Determines the material’s ability to stretch before breaking, providing insight into its ductility and forming capabilities. 

Casting Soundness
Acoustic Emission Testing

Detects high-frequency emissions from potential defects, ensuring the casting's overall soundness. 

Hardness Distribution
Microhardness Testing (Vickers or Knoop)

Measures hardness variations across different areas of the casting to assess uniformity and quality. 

Corrosion Resistance
Salt Spray Test (ASTM B117)

Evaluates the casting's ability to resist corrosion when exposed to salt-laden environments, important for automotive and marine applications. 

Weldability
Weldability Testing (ASTM E1941)

Assesses the ability of the casting to be welded without forming defects or weakening the material. 

Stress Relief
Stress Relief Testing (Residual Stress Mapping)

Measures residual stresses within the casting after cooling to ensure dimensional stability and prevent deformation. 

Casting Thickness Uniformity
Ultrasonic Thickness Testing

Uses ultrasonic waves to verify uniform thickness throughout the casting, crucial for ensuring consistent material properties. 

Tensile Modulus
Tensile Testing (ASTM E8)

Measures the stiffness of the material under tension, important for parts that will be subject to heavy loads. 

Coefficient of Friction
Tribological Testing

Determines the friction characteristics of the casting surface, which is vital for moving parts or wear-resistant applications. 

Non-Destructive Testing (NDT)
X-ray, Ultrasonic, or Eddy Current Testing

Detects internal flaws, such as cracks, voids, or inclusions, without damaging the casting, ensuring high structural integrity. 

Inspection Techniques in Hot Chamber Casting

X-Ray Radiography
Parameters - Penetration Depth

Value/Range  - 1 - 50 mm  

Aerospace (structural castings), Medical (implant housings) 

X-Ray Radiography
Parameters - Resolution

Value/Range  - 1 - 10 µm 

Automotive (engine blocks), Electronics (sensor casings) 

Ultrasonic Testing (UT)
Parameters - Frequency

Value/Range - 2 - 10 MHz 

Defense (firearm components), Marine (corrosion-proof parts) 

Ultrasonic Testing (UT)
Parameters - Detection Depth

Value/Range - 5 - 100 mm  

Renewable Energy (turbine components), Rail (brackets) 

Dye Penetrant Testing (DPT)
Parameters - Crack Detection Sensitivity

Value/Range - 10 - 100 µm 

Industrial (pump housings), Medical (surgical tools) 

Magnetic Particle Inspection (MPI)
Parameters - Field Strength

Value/Range - 500 - 2000 Gauss 

Automotive (drivetrain gears), Robotics (motor housings) 

Eddy Current Testing (ET)
Parameters - Conductivity Range

Value/Range - 0.5 - 60 MS/m 

Electronics (micro-housings), Aerospace (lightweight panels) 

Dimensional Inspection (CMM)
Parameters - Accuracy

Value/Range - ± 2 - 10 µm  

Automotive (chassis components), Medical (precision parts) 

Optical Inspection (Vision Systems)
Parameters - Resolution

Value/Range - 0.5 - 5 µm 

Telecommunications (RF shielding), Consumer Goods (decorative finishes) 

Leak Testing (Helium or Air Pressure)
Parameters - Pressure Sensitivity

Value/Range - 0.1 - 10 bar 

Aerospace (fuel injectors), Automotive (cooling system parts) 

Hardness Testing (Brinell, Vickers, Rockwell)
Parameters - Hardness Range

Value/Range - 50 - 250 HB / 100 - 700 HV 

Marine (valve components), Defense (armor casings) 

Metallurgical Analysis (SEM, EDS, XRF)
Parameters - Elemental Accuracy

Value/Range - ± 0.01% 

Aerospace (alloy verification), Electronics (PCB shielding) 

Thermal Imaging (Infrared NDT)
Parameters - Temperature Sensitivity

Value/Range - 0.1 - 5°C 

Renewable Energy (solar panel brackets), Robotics (AI-driven actuators) 

hot chamber casting services
hot chamber casting services

Industry Applications

Automotive
High-performance drivetrain & transmission parts

EV battery enclosures, turbocharger housings, sensor brackets 

Aerospace
Lightweight structural and avionics components

Flight control system parts, precision fuel injectors, UAV components 

Electronics & Semiconductors
Thermal management & shielding solutions

EMI/RF shielding, precision sensor casings, microprocessor housings 

Medical & Healthcare
High-precision, biocompatible surgical tools

Prosthetic joints, endoscopic instrument casings, robotic surgery components 

Industrial Automation
Heavy-duty mechanical and pneumatic components

High-torque gear casings, servo motor housings, industrial control panels 

Defense & Firearms
High-strength, compact weapon & tactical parts

Military-grade optical mounts, firearm trigger assemblies, drone casings 

Telecommunications
Compact, high-frequency signal transmission parts

Satellite communication housings, 5G antenna brackets, RF connectors 

Robotics
Lightweight, high-strength robotic elements

Robotic arm joints, motor housings, AI-driven actuator parts 

Renewable Energy
Corrosion-resistant power generation components

Wind turbine control housings, solar panel mounting brackets, fuel cell enclosures 

Marine & Offshore
Saltwater-resistant mechanical and electrical parts

Navigation instrument casings, underwater sensor enclosures, corrosion-proof brackets 

Luxury Goods & Watches
High-finish, intricate metal components

Watch casings, premium pen bodies, decorative metal accents 

Rail & Transportation
Durable, high-precision railway components

Train door handles, suspension system brackets, brake system enclosures 

Agriculture & Heavy Machinery
High-durability, impact-resistant parts

Hydraulic pump covers, tractor control housings, reinforced brackets 

Home Automation & Smart Devices
Compact, high-performance enclosures

Smart lock housings, home security system components, IoT device frames 

3D Printing & Prototyping
Rapid prototyping of metal components

Custom-designed heat sinks, prototype electronic enclosures, precision small-scale parts 

Frigate Your Trusted Hot Chamber Die Casting Partner

At Frigate, you get a reliable partner for hot chamber die casting services. Our engineers work closely with you to ensure your designs succeed in mass production. Hot chamber die casting products tailored to your specific needs are delivered on time. 

Benefit from skilled handling of materials and experience in producing parts for various industries. You can expect high-quality components and services that meet and exceed your expectations. 

Industries We Serve

What You Gain with Us

We make your profitability and operations easier with practical approach.

hot chamber casting services
hot chamber casting services

↓ 7-8%

OPS COST

hot chamber casting services

↓ 2-3%

COGM

hot chamber casting services

3X

Aggregation

hot chamber casting services

↑ 25%

Machinery Utilisation

hot chamber casting services

↓ 50%

Expedition

hot chamber casting services

↑ 30%

Frigater Revenue

Drive Innovation with Frigate's Hot Chamber Casting for Automotive Parts

Frigate offers top-notch hot chamber casting for the automotive industry. Our process ensures high precision and perfect fit for engine components and transmission cases. Take advantage of fast production cycles, excellent surface finishes, and durable components. Trust Frigate for efficient, high-quality casting that meets automotive standards and keeps production costs low. 

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

What is the main advantage of using hot chamber casting for zinc alloys?

Hot chamber casting is great for zinc alloys because it allows quick and efficient melting. The molten metal stays in the machine during the process, reducing exposure to air. This helps make parts with smooth surfaces and fewer defects. 

How does temperature control affect the quality of hot chamber castings?

Temperature control is very important in hot chamber casting. If the metal is too hot, it can cause problems like bubbling or porosity. Keeping the right temperature helps produce strong, high-quality castings with fewer flaws. 

Why is a gooseneck design important in hot chamber machines?

The gooseneck design in hot chamber machines helps direct molten metal from the furnace to the die. This shape prevents metal from cooling too quickly and ensures smooth flow. It is crucial for making detailed and accurate castings. 

How does the cycle time in hot chamber casting compare to other methods?

Hot chamber casting usually has a shorter cycle time than other methods, like cold chamber casting. The molten metal is already in the machine, allowing quicker filling and solidification. Faster cycles mean more parts can be produced in less time. 

What defects are common in hot chamber casting, and how can they be minimized?

Porosity and surface imperfections are common defects in hot chamber casting. Proper temperature control and material selection are key to minimizing these issues. Regular maintenance of the casting machine also helps ensure consistent quality and reduce defects. 

We'd love to Manufacture for you!

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ã…¤

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