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This section provides an overview for casting dies as well as their applications and principles. Also, please take a look at the list of 17 casting die manufacturers and their company rankings. Here are the top-ranked casting die companies as of December, 2024: 1.American Precision Die Casting, 2.PHB Inc, 3.G & M Die Casting..
Table of Contents
Die casting is a type of casting method in which molten material is heated and poured into a mold.
The materials to be melted are metals such as aluminum, zinc, and magnesium. The manufacturing process is automated and suitable for mass production. An advantage is low cost, since once a die is made, it can be used continuously.
The term "Casting Die" refers not only to the manufacturing method but also to the product itself made by this method. Compared to other casting methods, die casting has a shorter history since the method was established, and new methods are being created even today.
Die casting is used in a wide variety of automotive parts, including parts of the body, covers around water pumps, engines, transmissions, compressors for air conditioners, and other parts with complex shapes.
Recently, with the need for electrification and weight reduction, they are also used in parts around power steering and covers for control units. Aluminum die casting is often used for automotive parts because they are often complex and require good heat dissipation; although there are alternatives using ABS and other resins, aluminum die casting is still an essential part of automotive parts today.
Casting Die products are also used in familiar home appliances such as TVs, air conditioners, washing machines, and electric cookers.
Like automotive parts, many home appliances are precision products, and mass production is required. Therefore, Casting Die is used because of its ability to handle complex shapes and to keep production costs low.
Casting Die products also contribute to miniaturization and weight reduction. Therefore, they are often used for products that require lightness, such as golf equipment, cameras, fishing equipment, OA equipment, and cell phones.
There are several types of Casting Die. The general construction method is the following procedure:
Special methods are as follows:
After the molds are pressed together, air is removed to create a vacuum. After the vacuum is created, hot water is injected and the product is removed. Since air is removed, oxides are suppressed and high quality products can be produced.
After the molds are pressed together, the inside of the mold is filled with oxygen. After filling, hot water is injected and the product is removed. This method has the feature of preventing the generation of nests due to the decompression caused by the oxidation reaction. This method is suitable for products that require strength.
After the molds are aligned, hot water is injected. When the hot water is half solidified, the mold is partially re-pressurized. By re-pressurizing, hot water can be replenished to the area where shrinkage has occurred during solidification, thus making it possible to produce products with fewer cracks.
Casting is a method of forming products by pouring liquid metal melted in a high-temperature furnace into molds made of sand, metal, or wax. Basically, no external force is applied, but the liquid metal's own weight and subsequent flow is used.
Casting Die, on the other hand, is a further development of casting, in which liquid metal is injected into a mold under pressure to form it.
In casting, the high-temperature liquid metal is not so fluid that it takes time to spread to every corner of the mold under its own weight alone. Furthermore, it shrinks as it solidifies, so dimensional changes and wrinkles created during flow are likely to cause defects.
On the other hand, in Casting Die, pressure is applied to the liquid metal and injected into the mold, so the metal is quickly spread to all corners of the mold. Because it is formed under pressure, it has high dimensional accuracy and excellent surface roughness. This allows for high productivity in mass production.
Another major difference from casting is that finishing and inspection processes can be reduced due to the high quality.
Undercut shapes are disadvantageous
Casting Die is used to extrude the product after molding, and it is difficult to extrude horizontal holes or flange parts that are perpendicular to the direction of extrusion. Such parts are called undercut shapes. To make products with undercuts, we use cores that can be removed after casting. This makes the mold more complex and increases the manufacturing cost.
Lower strength than cast products
In Casting Die, high-temperature liquid metal is forced into the product at high speed and high pressure, causing air that cannot escape and evaporated gases from the mold release agent that separates the mold from the product to be entrained in the product. This inevitably results in the inclusion of internal defects and a reduction in strength.
When plastic forming is applied by external force, such as hot forging or cold forging, it is possible to crush these defects, and thus the strength of the product is superior to that of Casting Die. Recently, however, Casting Die methods have been developed that solve this problem.
High initial cost
The disadvantage of Casting Die is that the initial cost is high because of the complicated mold shape and the need to use expensive materials with excellent resistance to heat and aluminum corrosion. In addition, since the die is repeatedly subjected to high temperature and high pressure loads hundreds or thousands of times a day, it does not have a long service life, resulting in high running costs.
*Including some distributors, etc.
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PHB Inc., established in 1984 with a history in the industry dating back as far as 1096 and headquarters in the USA, is a custom manufacturer and supplier of die cast tooling, parts, and supplies. The company's manufacturing capabilities include aluminum and zinc die casting, precision CNC machining, plastic and rubber molding, tool and die design, and production. It also provides final part finishing and product assembly. The company provides services, including engineering, product development, and prototyping. Other services include millipore testing, leak testing, impregnation, and cryogenic deflashing.
American Precision Die Casting (APDC), founded in 2006 in Cuba, Missouri, is a manufacturer rand supplier of aluminum die-casting services. The company is built on a 40,000-square-foot facility housing designers, machinists, engineers, and customer support agents. The company offers various die-casting services, including design, engineering, manufacturing, and finishing, all of which are provided through SMED (single-minute exchange of dies) and Kanban programs. American Precision Die Casting supports automotive aftermarket, agriculture, commercial vehicles, military and defense industries, offering customer support and maintenance of business connections.
G & M Die Casting, established in 1978 and located in Wood Dale Illinois, is a manufacturer of aluminum die casting. The company is built on a 70,000-square-foot facility and houses an experienced team of engineers and machinists. It is a single-source provider of cast, machined, and painted mechanical components. It is an ISO 9001:2015 certified company providing die-casting services, including design, engineering, manufacturing, and finishing. The company’s products are used in the automotive, aerospace, and medical industries.
MES, Inc., founded in 1997, is an American manufacturer with its global headquarters located in Lewis Center, Ohio, specializing in die casting solutions. The company offers custom die-cast metal parts using various materials such as aluminum, brass, and copper, produced through hot and cold chamber machines. It also provides investment casting or lost wax casting for materials like carbon steel, grey iron, and stainless steel. The company further offers services in hot and cold forging, extrusion molding, as well as assemblies and sub-assemblies utilizing adhesives, fasteners, and welding technologies. Computer numerical control (CNC) machining is another service offered by the company.
Apex Aluminum Die Casting Co. Inc. is a manufacturer of aluminum die castings and zinc die castings. Established in 1980 and located in Piqua, Ohio, the company specializes in developing and delivering die castings from concept to final product. The company offers assembly and finishing services, including machining, sanding, and painting as well as tool manufacturing, conversions, maintenance, and repair services. The company provides support in the manufacturing and design of new mold, the transfer of existing die-cast tooling, and the processing of conversions from sand and permanent mold applications.
J&M Precision Die Casting, Inc., a subsidiary of Rhenium Alloys, Inc., established in 1968 and headquartered in Elyria, Ohio is a manufacturer specializing in Aluminum die castings and zinc castings. The company offers various products, including Electric motor components, Security hardware, and Decorative hardware. The company also offers services such as assembly and testing, mold building, and product design, as well as building custom machines for specific requirements. It is a member of The North America Die Casting Association and some of its clients are the agricultural and automotive Industries.
A&B Die Casting, founded in 1945 and located in Hercules, California, is a manufacturer and supplier of Industrial products. The company offers a wind range of products, including IV pump housing, Diesel and fuel filter housing, and hammer crusher, as well as various services, such as prototyping, aluminum & zinc die casting, and engineering and design-for-manufacturing support. The company uses updated computer engineering software to create prototype of files to determine necessary improvements before the production of specialized parts. It serves architectural lighting, medical hardware, and telecommunications Industries, creating solutions for production needs.
P&R is a manufacturer and supplier of mechanical components and assemblies in New Jersey and was established in 1970. The company provides technical support for designing, developing, producing, and supplying custom fasteners and casting for the OEM market. The manufacturing capabilities of P&R include cold heading, casting, stamping, machining, and injection molding, and the products are crafted using various materials like carbon, alloy, and stainless steel, with aluminum, and brass, and some non-metals like plastic, and rubber. Industries such as Automotive, Medical Equipment, Appliances, Consumer Products, and Aerospace benefit from P&R products.
Industrial Pattern & Manufacturing, Located in St. Columbus, OH, is a manufacturer of patterns, models, and molds used in industrial, aerospace, and automotive applications, established in 1946. The company has products such as pep sets, trays, airfoils, paper parts, and shell boxes with wood patterns, match plates, flexible patterns, and shell patterns. The company has capabilities and services such as permanent molds, core coxes, prototyping, scale models, and CNC machining with activities such as milling & drilling, boring, taping, threading, and deep cavity cutting.
M&P Manufacturing USA is a metal and plastic parts manufacturer founded in 1992 and based in Brooksville, Florida with a secondary office in Shenzhen, China. The company is an exclusively built-to-print OEM provider that does not distribute any products under its own branding. The company offers plastic injection molding, precision CNC machining, plastic and metal extrusion, tooling, and other services for the development, fabrication, and finishing of components used in aerospace, automotive, construction, and general industries.
Plainville Machine and Tool Company, Inc., established in 1965 and based in Bristol, Connecticut, is an American manufacturer specializing in custom metal stamping tools and dies. With the aid of design platforms like CADKEY and AutoCAD, PM&T offers tailor-made designs to meet diverse specifications, including complex tooling, in-die tapping, assembly in the tool, or multiple strip tooling requirements. The company produces these tools and dies, such as blanking, compound, and forming dies, as well as inspection gauges and fixtures, using electrical discharge machines. PM&T's products adhere to specifications and close tolerances demanded by various industries, including automotive, aerospace, hardware, medical, and telecommunications.
Ryobi Limited, established in 1943 and headquartered in Hiroshima, Japan, is a manufacturer components and equipment. Its diverse product range includes die-cast components for the automotive sector, builders' hardware for construction, printing equipment for the printing industry, electric power tools, and a range of outdoor solutions. The company plays a pivotal role in providing components for essential industries and offers an array of tools and equipment for various applications, making them a significant player in the manufacturing and tool industry.
Sunrise Metal Technology Co., Ltd., founded in 2013, is a Chinese manufacturer based in Kunshan, Jiangsu, specializing in die casting solutions. The company provides a range of services centered around aluminum die casting manufacturing and computer numerical control (CNC) machining, specifically for aluminum materials. This includes CNC milling, drilling, tapping, and boring processes. It also offers rapid prototyping services utilizing both additive and subtractive manufacturing techniques. Optional surface finishing services are available for both the die casting and machining processes. The company serves various industries with its die casting and machining capabilities, notably catering to the automotive, marine, medical, and telecommunications sectors.
ZETWERK Manufacturing USA Inc., established in 2018, is a manufacturing services provider offering unlimited manufacturing capacities in every area of manufacturing. The company has capabilities such as high pressure & low pressure die casting, sheet metal fabrication, metal stamping & forming, metal injection molding, and CNC milling and machining. The company provides services like prototyping, mass production, warehousing, and inventory management. The company in Mesa, Arizona, AZ, is ISO 9001:2015 and AS9100D certified and serves the industrial machinery & equipment, transportation, construction & infrastructure, energy, and electronics & appliance industries.
Dynacast, a Form Technologies Company, founded in Charlotte, NC in 1936 is a manufacturer of precision components using proprietary die-casting technology and tooling techniques. The company's product portfolio includes die casting materials, Optical Components, Machined Parts, Custom Fasteners and intricate components for electronic devices, circuit boards, and telecommunications equipment. Their products are used in markets such as Automotive and Transportation, Telecommunications, Industrial Automation, Healthcare and Medical Devices and Aerospace and Defense.
Spectron Manufacturing, Inc., founded in 2008 with headquarters in the USA, is a custom manufacturer of die castings and machined parts. The company's capabilities include die, sand, and investment casting, and it also provides precision CNC machining, lathe work, milling, plastic injection molding, and CMM inspection and has experience handling zinc, magnesium, aluminum, steel, titanium, and plastics. As a custom manufacturer, from design to specifying parts for cost-effective casting production to production, the company works with clients to meet their manufacturing-specific needs.
Yamanaka & Co., Ltd., founded in 1858 and established in 1863 with headquarters in Ina City, Nagano, Japan, is a smelter, contract manufacturer, and supplier of base metals, industrial chemicals, and processed metal products. The company's products include antimony oxides and cathodic protection metals (zinc, aluminum, and magnesium), and it also offers the contract production of aluminum products and processed metal construction materials. It specializes in the production and supply of raw chemical compounds, including copper compounds, cobalt compounds, iron-based compounds, zinc compounds, and barium compounds. The company serves markets including consumer product manufacturing, construction, chemical processing, water treatment, and communications.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | American Precision Die Casting |
12.2%
|
| 2 | PHB Inc |
10.8%
|
| 3 | G & M Die Casting. |
7.9%
|
| 4 | MES, Inc |
7.9%
|
| 5 | Apex Aluminum Die Casting Co. Inc. |
6.7%
|
| 6 | J&M Precision Die Casting, Inc. |
6.5%
|
| 7 | Dynacast, a Form Technologies Company |
6.5%
|
| 8 | ZETWERK Manufacturing USA Inc. |
6.2%
|
| 9 | Spectron Manufacturing |
6.0%
|
| 10 | M&P Manufacturing USA |
5.0%
|
Derivation Method
The ranking is calculated based on the click share within the casting die page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
11 | 78.6% |
|
Japan
|
2 | 14.3% |
|
China
|
1 | 7.1% |
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