High Pressure

Die Casting

Automated, industry leading excellence

CastAlum has been high pressure die casting in the heart of Wales for over twenty years, so it’s fair to say we know a lot about the process!

About High Pressure Die Casting

A brief history of high pressure die casting

While high pressure die casting (HPDC) has been around for several decades now, in its infancy it was considered an inferior process to its main competitor: gravity die casting. Some of the original problems with HPDC were:

  • Expensive to set up
  • More suited to long runs and large quantities
  • Higher porosity and generally lower quality

For several years parts produced by the HPDC process were understood to be cheaper, but of inferior quality. To further emphasis this, HPDC utilized the LM24, considered a low-level material in terms of both quality and price.

Refining the process

As die casting machine manufacturers such as Buhler Prince made their equipment more robust and predictable, the level of performance and quality of the parts began to improve. These advances included:

  • Control mechanisms on shot speed, clamping, etc.
  • The ability of a machine to automatically shut down a process
  • Quality control from parts per minute to zero defect and then to single part rejection

The necessity to produce parts right first time has resulted in an industry-leading production process. Through the constant refinement of an already mature method, CastAlum has achieved levels of excellence that would have scarcely been thought possible back when the company was founded at the turn of the century.

The future of HPDC

Even with all these recent improvements, technical progress continues to be made. Nowhere is this more apparent than in our provision of parts to the expanding electric vehicle (EV) market. As a visionary within the industry, CastAlum is always striving to find new levels of performance and engineering distinction through a range of possibilities converted into successes, including:

  • Innovation in engineering design and enhancements to in-process controls
  • Light weighting whilst providing yet more complex geometries with improved integrity and strength.
  • Unparalleled tooling durability with innovative additive manufacturing

Armed with over twenty years of experience and ever-increasing skillset, we’re looking forward to providing the continuous improvement and competitive benefits of high pressure die casting to our customers for the next twenty years too!

A brief history of high pressure die casting

While high pressure die casting (HPDC) has been around for several decades now, in its infancy it was considered an inferior process to its main competitor: gravity die casting. Some of the original problems with HPDC were:

  • Expensive to set up
  • More suited to long runs and large quantities
  • Higher porosity and generally lower quality

For several years parts produced by the HPDC process were understood to be cheaper, but of inferior quality. To further emphasis this, HPDC utilized the LM24, considered a low-level material in terms of both quality and price.

Refining the process

As die casting machine manufacturers such as Buhler Prince made their equipment more robust and predictable, the level of performance and quality of the parts began to improve. These advances included:

  • Control mechanisms on shot speed, clamping, etc.
  • The ability of a machine to automatically shut down a process
  • Quality control from parts per minute to zero defect and then to single part rejection

The necessity to produce parts right first time has resulted in an industry-leading production process. Through the constant refinement of an already mature method, CastAlum has achieved levels of excellence that would have scarcely been thought possible back when the company was founded at the turn of the century.

The future of HPDC

Even with all these recent improvements, technical progress continues to be made. Nowhere is this more apparent than in our provision of parts to the expanding electric vehicle (EV) market. As a visionary within the industry, CastAlum is always striving to find new levels of performance and engineering distinction through a range of possibilities converted into successes, including:

  • Innovation in engineering design and enhancements to in-process controls
  • Light weighting whilst providing yet more complex geometries with improved integrity and strength.
  • Unparalleled tooling durability with innovative additive manufacturing

Armed with over twenty years of experience and ever-increasing skillset, we’re looking forward to providing the continuous improvement and competitive benefits of high pressure die casting to our customers for the next twenty years too!

Our Die Casting Process

Contact us about high pressure die casting here!

You can also email info@castalum.com or call +44 (0) 1938 557 557

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Learn more about high pressure die casting

111, 2021

New Die Casting Pit Timelapse

We’re awaiting delivery of our new die casting cell from Buhler Prince in January 2022, but before it arrives, we captured a timelapse of the pit being dug!

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