Die Casting Services
Frigate’s die casting services deliver high output production, cost efficiency, and flexible design options, which are ideal for non-ferrous metal products. Our advanced facilities handle diverse designs and materials, ensuring high-quality parts tailored to various industry needs.
Our Clients
Advantages of Die Casting Services
Excellent Dimensional Accuracy
Die casting provides tight tolerances, ensuring that parts fit precisely. This reduces machining requirements and enhances overall product consistency and performance.
Superior Surface Finish
The die casting process produces smooth surfaces, minimizing post-production finishing. This enhances aesthetic appeal and reduces the need for additional coatings.
High Production Efficiency
Die casting enables rapid cycle times, allowing for high-volume production. This efficiency reduces lead times, meeting tight deadlines without compromising quality.
Material Versatility
Die casting accommodates various alloys, including aluminum, zinc, and magnesium. This versatility allows for tailored properties, optimizing performance for specific applications and industries.
High-Speed Die Casting for Non-Ferrous Metals
The die casting process at Frigate is the fastest method for producing precise non-ferrous metal products. Using reusable molds, we achieve high-speed production and the ability to create a broader range of shapes and sizes compared to other casting methods.
Our die casting can be fully automated, enhancing efficiency and reducing costs. This technique is suitable for manufacturing commercial, consumer, and industrial products. It produces medium-sized parts with complex structures, ensuring high-quality results tailored to your specifications.
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Our Die Casting Process
The process begins with designing the part and creating a mold. Engineers use CAD software to develop precise specifications and ensure the mold meets all requirements.
The mold is preheated to optimal temperatures. This enhances the flow of molten metal and reduces cooling time, ensuring better surface quality and dimensional accuracy.
Selected metal alloys are heated in a furnace until they reach a liquid state. The molten metal is then prepared for injection, ensuring it is impurities-free.
The molten metal is injected into the mold under high pressure. This rapid injection fills the mold, capturing intricate details and minimizing air pockets.
Once filled, the metal is allowed to cool and solidify. This process typically takes seconds to minutes, depending on the part's thickness and material properties.
After solidification, the mold opens, and the finished part is ejected. The part is inspected for quality and precision before moving on to any required finishing processes.
Post-Processing Services in Die Casting
Die-cast components often require post-processing to enhance surface finish, strength, and functionality. These processes ensure tight tolerances, corrosion resistance, and aesthetic appeal for various industries.
Automotive (engine housings), Aerospace (brackets), Electronics (heat sinks)
Surface Roughness: Ra 0.8 - 3.2 µm
Automotive (transmission cases), Aerospace (aircraft parts), Medical (implants)
Consumer Goods (decorative parts), Electronics (housings)
Automotive (body components), Aerospace (fasteners), Electronics (connectors)
T5 (Aging: 140-200°C)
T6 (Solution Treatment + Aging)
Aerospace (structural components), Automotive (suspension parts)
Automotive (oil pans), HVAC (compressor housings)
Automotive (engine blocks), Aerospace (fuel system parts)
Automotive (gearboxes), Aerospace (frames), Industrial Equipment (pumps)
Powder Coating (50-150 µm)
E-Coating (20-30 µm)
Consumer Goods (appliances), Automotive (chassis components)
Aerospace (lightweight structures), Electronics (enclosures)
Methoding in Die Casting
Automotive (engine blocks), Aerospace (brackets)
Small (electronic connectors), Large (automotive housings)
Automotive (transmission cases), Industrial (gearboxes)
High-volume (automotive), Aerospace (complex shapes)
High-precision (electronics), Heavy-duty (machinery)
Complex parts (aerospace, defense), Thin-wall (electronics)
High-temperature (aerospace, automotive), High-volume (industrial)
Precision parts (electronics), Heavy parts (automotive)
Aerospace (structural parts), Automotive (brackets, housings)
Thin-wall (electronics), Thick-wall (machinery, automotive)
Rapid (consumer goods), Standard (automotive, industrial)
Die Casting Materials
By leveraging the unique attributes of each material, die casting allows for the optimization of strength, weight, and thermal properties, making it suitable for demanding applications across multiple industries.
It is known for its strength, durability, and resistance to corrosion. It's used in industries like aerospace, automotive, and medical devices for parts that need to withstand tough conditions.
Zinc alloys are renowned for their superior strength and dimensional stability. With a high resistance to deformation and excellent casting properties, they are often used for parts requiring precise dimensions, such as automotive components and consumer electronics. Alloys like Zamak 3 and Zamak 5 provide excellent surface finishes and are perfect for high-volume production, ensuring durability and longevity.
Magnesium alloys are the lightest structural metals available, offering significant weight reduction without compromising strength. They have excellent machinability and good resistance to stress corrosion cracking. Common grades such as AZ91D are ideal for aerospace and automotive applications. Their superior thermal properties also make them suitable for heat-sensitive applications.
Copper alloys, including brass and bronze, provide outstanding electrical conductivity and thermal resistance. They are often used in applications that require excellent thermal management, such as electrical connectors and heat exchangers. Their high strength and corrosion resistance make them ideal for specialized industrial components, although they are less common in high-volume die casting due to higher material costs.
Lead alloys are primarily used in applications where high density and corrosion resistance are essential, such as in battery manufacturing and radiation shielding. While they offer excellent protection against radiation, their use is becoming limited due to environmental regulations. High-quality lead alloys ensure longevity and reliability in specific applications, although they are not as versatile as other materials in the die casting process.
Precision-Driven Die Casting Services
We offer a range of die-casting processes customized to meet your project requirements. Our advanced die casting capabilities are designed for manufacturers seeking unique and highly functional designs.
We take full responsibility for the entire process, from initial design support to precision machining, metal finishing, and final assembly. This streamlined approach guarantees quality and efficiency at every stage of production.
Compliance for Die Casting Services
Frigate Die Casting Services upholds the highest compliance standards to ensure precision and reliability. The company follows stringent regulatory guidelines to maintain quality, safety, and environmental responsibility throughout its production process. This approach guarantees that all products meet industry-specific requirements and customer expectations.
Quality management system standard ensuring continuous improvement and customer satisfaction.
Restriction of Hazardous Substances directive, ensuring products are free from harmful materials.
The aerospace industry standard for quality management systems ensures products meet critical safety and performance requirements.
Underwriters Laboratories certification for product safety, ensuring designs comply with electrical safety standards.
Registration, Evaluation, Authorization, and Restriction of Chemicals for safe chemical use in production.
Commitment to sourcing materials free from conflict minerals, ensuring ethical production practices.
Tonnage / Capacity in Die Casting
Die casting machines are classified by tonnage (clamping force), which controls mold stability, injection pressure, and material flow. Higher tonnage supports large, complex parts, while lower tonnage ensures precision and faster cycles for smaller components.
Small (electronics, handheld tools) to Large (automotive engine blocks, aerospace frames)
Small (connectors, brackets) to Heavy (gear housings, pump casings)
Small (sensor enclosures) to Large (chassis, engine components)
High-speed (thin-walled parts) to Standard (structural components)
Toggle (fast cycle), Direct (precision), Hydraulic (large parts)
Small (zinc, magnesium) to Large (aluminum, brass)
High (thin-wall automotive parts), Standard (industrial castings)
Fast (consumer electronics), Medium (automotive), Slow (complex aerospace parts)
Low-volume (prototype dies) to High-volume (mass production dies)
Thin-wall (shorter time), Thick-wall (longer time)
Small (lightweight parts) to Large (deep cavities)
Lightweight (automotive, aerospace) to Heavy-duty (industrial, defense)
Dimensions in Die Casting
Die casting dimensions influence mold cavity design, metal flow dynamics, solidification rates, and dimensional stability. Precise control over these factors ensures minimal defects, optimal mechanical properties, and consistent part accuracy across high-volume production.
Large (automotive engine blocks, aerospace frames)
Thin (electronics, housings) to Thick (industrial casings)
Shallow (precision parts), Steeper (complex geometries)
Tight (medical, aerospace), Standard (automotive, industrial)
Stress reduction in corners (automotive, machinery)
Controlled in multi-cavity molds (high-precision components)
Small (electronics connectors), Large (structural components)
Thin, elongated structures (heat sinks, enclosures)
Smooth (aerospace, medical), Standard (automotive, industrial)
Varies by material (aluminum, magnesium, zinc)
Tolerance for Die Casting Services
Achieves fine precision in component dimensions based on part complexity and molding methods.
Maintains consistent wall thickness for optimal strength, thermal conductivity, and reduced shrinkage.
Ensures straight lines are maintained across the part to avoid distortion or misalignment during use.
Ensures part faces remain flat within specified limits to avoid gaps in assembly or warping.
Surface roughness tolerance, depending on part function, affecting texture and coating compatibility.
Ensures that circular components, like shafts or rings, maintain their geometry for proper fitting.
Maintains tight angular tolerance for critical alignment and functional assembly of parts.
Ensures the correct hole size for inserts, fasteners, and fittings, maintaining dimensional precision.
Precision control over the core-pulling process to maintain part integrity and prevent defects.
Provides consistency in part release from molds, preventing potential damage or mold locking.
Ensures correct thread depths for bolts or fasteners that require precise threading.
Maintains precise tolerances on bores to ensure proper insertion of pins, shafts, or bearings.
Ensures that holes, diameters, and surfaces are aligned, critical for rotating components or assemblies.
Controls the angle of tapered features in the casting for proper fitting and stress distribution.
Ensures smooth transitions between surfaces, critical for reducing stress points and improving durability.
Maintains the correct 90-degree angle between two surfaces, important for part assembly and fitment.
Ensures uniform alloy composition throughout the part, avoiding weak points or inconsistencies in material properties.
Accounts for material shrinkage during cooling to ensure the part meets final dimensional requirements.
Controls any bending or warping of thin sections of parts under stress or after cooling.
Minimizes the distortion in complex shapes due to thermal gradients and residual stresses in the casting.
Ensures consistent coating thickness for protection or aesthetic finish without affecting part fit.
Manages the acceptable gap between components during assembly, critical for functionality.
Ensures a smooth and even surface finish, particularly for areas with casting seams or bead marks.
Quality Testing Standards for Die Casting Services
Verifies critical dimensions and geometric tolerances with high precision to ensure parts meet design specifications.
Measures a material’s ability to conduct heat, important for components exposed to high temperatures or heat cycles.
Analyzes the microstructure of the cast material, identifying phase distribution, grain structure, and defects.
Measures hardness at a micro-scale, suitable for testing small or thin parts that require high precision.
Measures the material’s ability to stretch or deform without breaking, providing insight into its toughness.
Detects surface cracks and flaws by applying a dye, which is drawn into cracks to make them visible under UV light.
Tests a material's resistance to damage from cavitation, crucial for parts exposed to high-speed fluid flow.
A 3D imaging technique to detect shrinkage porosity and voids within the material that could affect strength.
Assesses the tensile strength and ductility of a material at elevated temperatures to simulate real-world operating conditions.
Determines a material's susceptibility to stress corrosion cracking under specific environmental conditions.
Provides a hardness profile across different sections of a casting to identify uniformity and detect soft spots.
Evaluates how a casting material withstands repetitive or fluctuating stress loads over time, simulating real-world conditions.
Measures the material's expansion or contraction in response to temperature changes to assess dimensional stability.
Simulates high-temperature environments to assess a material's ability to resist oxidation and maintain strength.
Tests a part's resistance to vibrations and cyclic loading, especially in automotive and aerospace applications.
Detects the susceptibility of a material to cracking due to absorbed hydrogen during manufacturing or service.
Analyzes the material flow during the die-casting process to identify potential casting defects such as cold shuts or misruns.
Ensures cast components are suitable for soldering or electronic assembly, essential for automotive or aerospace parts.
Tests the resistance of die-cast parts to environmental corrosion, often in saline or humid conditions, critical for durability.
Determines the stiffness of the material, providing critical data for components subject to stress and deformation.
Used for precise hardness measurement on fine features or thin sections, useful for assessing surface treatment effectiveness.
Evaluates the wear and tear of the die material by simulating repeated casting cycles under thermal and mechanical stress.
Tests the material’s resistance to degradation when exposed to specific chemicals, oils, or solvents, important for automotive or industrial parts.
Assesses material behavior under prolonged exposure to high temperatures and stress, crucial for aerospace and engine parts.
Determines the point at which a material begins to deform plastically, an essential property for structural components.
Inspection Techniques in Die Casting
Human visual or magnification tools
All industries (automotive, aerospace, electronics)
Value/Range - Up to 10 mm deep, resolution down to microns
Aerospace (engine components), Automotive (transmission)
Frequency range: 1 - 10 MHz
Depth range: 1 - 100 mm
Medical (implants), Aerospace (structural parts)
Tensile Strength: ±0.05 - ±0.2 mm
Automotive (brackets, engine parts), Electronics (enclosures)
Depth: 1 - 3 mm
Frequency: 100 kHz - 10 MHz
Automotive (safety components), Industrial (heavy machinery)
Resolution: 0.1 mm
Scan time: 10 minutes to several hours
Aerospace (turbine blades), Electronics (small, complex parts)
Sensitivity: 5 - 15 A/m
Depth: 1 - 5 mm
Automotive (brake components), Industrial (gears, pumps)
Sensitivity: low to high
Penetration time: 5 - 30 min
Aerospace (flange, brackets), Automotive (crankshafts, housing)
Resolution: 0.01 - 0.1 mm
Automotive (body parts), Aerospace (exterior components)
Range: 50 - 250 HV
Testing time: < 5 minutes
Automotive (engine parts), Industrial (bearings, gears)
Industry Applications of Die Casting
Cylinder heads, EV battery enclosures, Transmission housings
Aircraft brackets, Engine casings, Satellite structures
Heat sinks, RF shields, Sensor enclosures
Surgical tools, Implantable components, MRI housings
Hydraulic pumps, Gear housings, Robotic arm parts
5G antenna brackets, Fiber optic connectors, Base station housings
Wind turbine components, Generator housings, Power distribution units
Weapon frames, Radar components, Military-grade enclosures
Train couplers, Marine propellers, Engine covers
Compressor housings, Fan blades, Heat exchanger plates
Die Casting Capabilities for the Aerospace Industry
Die casting provides essential capabilities for the aerospace industry by enabling the production of lightweight, high-strength components. These features are crucial for enhancing aircraft performance and ensuring safety. By utilizing advanced aluminum and magnesium alloys, you can reduce weight without compromising structural integrity. The precise manufacturing process allows for intricate designs and tight tolerances, ensuring each part meets stringent industry standards. With the ability to scale production efficiently, die casting supports your need for rapid turnaround times and high-volume output, ultimately enhancing your operational efficiency and competitiveness in the aerospace market.
Industries We Serve
- Solid Progress
What You Gain with Us
We make your profitability and operations easier with practical approach.
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Solutions to Your Die Casting Challenges with Frigate
With high precision and tight tolerances, you can achieve the exact specifications required for your projects, minimizing the need for costly rework. The rapid production capabilities ensure you meet tight deadlines without compromising on quality, while the versatility of materials allows for tailored solutions to fit diverse applications. Additionally, advanced surface finishes reduce post-processing time, streamlining your production cycle and enhancing the overall efficiency of your operations. This comprehensive approach empowers you to optimize performance and deliver high-quality products to your customers.
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
Die casting primarily uses aluminum, zinc, magnesium, and copper alloys. Each material offers unique properties; for example, aluminum is lightweight and corrosion-resistant, while zinc provides excellent fluidity and strength.
Precision is achieved through advanced mold design, computer-aided manufacturing (CAM), and rigorous quality control measures. Tight tolerances are maintained using high-quality molds, and the injection process is monitored closely.
Lead time can vary based on project complexity and volume. Generally, initial prototypes can be produced within a few weeks, while larger production runs may take several weeks to months, depending on specific requirements.
Yes, die casting is highly effective for producing complex shapes with intricate details. The high-pressure injection process fills the mold, allowing for fine features and undercuts that other methods may struggle to achieve.
Various finishing processes, including machining, surface treatment, and plating, can enhance the final product. These processes improve aesthetics, reduce friction, and increase corrosion resistance, ensuring the part meets all functional and visual requirements.
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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. ㅤ
