Main wall thickness references
Aluminum: 1.5–4.5 mm. Zinc: 0.8–2.0 mm. Use these for initial design review and confirm them against the actual geometry.
Geometry & capacity
Die Casting Size, Weight & Wall Thickness
Review part dimensions, alloy-specific weight ranges, wall thickness and equipment requirements before confirming the production configuration.
Capacity references
Capacity at a Glance
Use the routine weight ranges and project examples below to prepare a drawing review. Confirm alloy, geometry, tooling and production conditions together.
- Aluminum routine net part weight
- 0.05–10 kg; one casting after gate removal, before machining
- Zinc routine net part weight
- 0.005–2 kg; one casting after gate removal, before machining
- Part size planning estimate
- 300–500 mm longest side, estimated from typical equipment; not a measured factory range or a 500 mm hard limit
- Local thin-wall review target
- 0.7 mm in zinc/Zamak with short flow paths, subject to tooling trials; not a general aluminum minimum
- Magnesium & copper alloys
- Weight and dimensions established for the exact grade and production configuration
- Machine clamping force
- 180–2,500 metric ton-force (tf); 11 machines
A 15 kg aluminum casting has been produced and requires a separate large-part assessment for a new project. A 1 g zinc part has been produced consistently in a specific hot-chamber project; this does not extend the routine range to every design. The highest weight, largest dimension and thinnest wall must be assessed together.
Drawing inputs
Part Dimensions & Shot Weight
Provide the overall length, width and height, projected area and local wall sections. Maximum and minimum dimensions are assessed against the mold design and production configuration. The drawing and selected production configuration establish the actual lower size limit.
A single external dimension cannot define a three-dimensional working envelope. The largest part size, highest weight and thinnest wall must be evaluated together for the same component.
The 300–500 mm longest-side reference is an estimate based on typical equipment, not a measured factory capability range or a 500 mm hard limit. The 18 × 5 mm small zinc-part example provides two dimensions only; no thickness was supplied, so it does not define a complete part envelope or minimum wall thickness.
Aluminum and zinc parts below 50 mm can be reviewed; aluminum designs also require a mold-layout and yield assessment.
Parts machined entirely from stock need a separate size review from castings. Machine travel, fixture clearance, tool access, workholding and part stability determine whether the required features can be machined and inspected.
- Single-part net weight
- Use the net weight of one casting after gate removal and before machining. Identify estimates and any different delivery stage separately.
- Complete shot requirement
- Parts in all cavities + runners + overflows. Review this metal requirement separately from the single-part net weight and the machine clamping-force rating.
Geometry & production review
Weight by Alloy
| Alloy | Routine component net weight | Conditions |
|---|---|---|
| Aluminum | 0.05–10 kg (50 g–10 kg) | One casting after gate removal and before machining; a 15 kg casting has been produced, but new large parts require a separate assessment |
| Zinc | 0.005–2 kg (5 g–2 kg) | One casting after gate removal and before machining; a 1 g part has been produced consistently in a specific hot-chamber project and is assessed as a project example |
| Magnesium | Subject to drawing and DFM review | Establish the range for the selected grade and production configuration |
| Copper alloy | Subject to drawing and DFM review | Establish the range for the specific copper alloy and process |
Component weight is considered separately from the metal required for a complete shot, including runners, overflows and the selected cavity count.
The 15 kg aluminum casting and 1 g zinc part are completed project examples outside the routine ranges. They do not establish repeatable weight limits for every geometry, alloy grade or tooling configuration.
Geometry & production review
Wall Thickness and Transitions
Local thin sections
A 0.7 mm local wall is a tooling-trial review target for zinc/Zamak with short flow paths. It is not a general aluminum capability; aluminum thin walls need their own filling and tooling review.
Thick sections & transitions
Local sections above 10 mm require review of transitions and internal quality requirements. Mark relevant functional and inspection criteria.
Wall design reference & acceptance conditions
Main wall thickness references are 1.5–4.5 mm for aluminum and 0.8–2.0 mm for zinc. The suitable thickness depends on the actual geometry, so these ranges guide initial design review rather than define every local section.
A 0.7 mm local thin wall is a tooling-trial review target for zinc/Zamak with short flow paths. It is not a general minimum for aluminum. Aluminum thin sections require their own alloy, filling-distance, local-structure and tooling-trial assessment before a thickness is agreed.
Local sections above 10 mm require assessment of thickness transitions and internal quality requirements. Geometry changes or flow analysis may be included in that assessment. Wall tolerance is agreed against the nominal thickness and specified measurement locations.
Geometry & production review
Equipment Ranges
Die Casting Machine Inventory
180–2,500 metric ton-force (tf); 11 machines
Machine selection depends on the alloy, projected area, die dimensions and shot requirement. Confirm the chamber type and alloy configuration for each project.
| Clamping force | Machines |
|---|---|
| 180T | 2 |
| 300T | 2 |
| 400T | 1 |
| 650T | 1 |
| 800T | 2 |
| 1,000T | 2 |
| 2,500T | 1 |
| Total machines | 11 |
Clamping force is a force rating. Part weight, shot weight and the usable part envelope must be reviewed separately.
The current die casting machine inventory is shown below and maintained on the Equipment page. Machine selection depends on the alloy, projected area, die dimensions and shot requirement. Confirm the chamber type and alloy configuration for each project.
Clamping force is a force rating, distinct from part mass and shot mass. Part dimensions, weight and thin-wall capability must be reviewed together for the selected machine and tooling.
Before submitting a drawing
Size and Weight Questions
What if projected area or net weight is not yet available?
Send the current CAD model and identify which values are estimates or unknown. Engineering can clarify the information needed to assess tooling and equipment.
Can a part outside the published references be reviewed?
Submit the drawing, grade, quantity and permitted design or process alternatives. Engineering reviews feasible next steps before a production commitment.
What happens if the design changes after review?
Identify the new drawing revision and changed features. Changes to geometry, alloy, cavity count or acceptance requirements need a renewed tooling and production review.
Engineering resources
Plan the Drawing and Tooling Review
Die Casting DFM Checklist Before Tooling Release
A drawing-based checklist for closing geometry, tooling, machining, finishing, inspection, and approval questions before die manufacture begins.
Read engineering guide →From DFM to T1: A Practical Die Casting Tooling Workflow
A practical view of tooling development from requirement review and mold concept through steel release, T1 sampling, correction, approval, and maintenance planning.
Read engineering guide →What Drives Die Casting Cost? A Total-Cost Review
A practical guide to tooling, material, geometry, process, machining, finishing, inspection, assembly, and change risks that shape total die casting cost.
Read engineering guide →
Drawing & project review
Review Your Part Geometry
Submit the drawing and the requirements below so engineering can assess the alloy, tooling and production configuration together.
Include with your RFQ
- Drawing and CAD revision; exact alloy grade.
- Overall length, width and height; projected area if available.
- Single-part net weight and the stage or estimate used.
- Wall-thickness distribution, local thin sections and thick transitions.
- Critical features, tolerances, finish and inspection requirements.
- Batch and annual quantities; target delivery and permitted design changes.