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High-pressure die-casting

High-pressure die casting with TOS: your production partner

At TOS – Technical Outsource Solutions, we support companies in developing and producing high-quality high-pressure die-casting products. High-pressure die-casting is the technology for manufacturing precise and complex aluminum or zinc parts with high dimensional accuracy and a smooth surface.

We advise on material selection, tolerances, and post-processing, and support you with 3D drawings and prototyping . Thanks to our international network of reliable partners, we offer competitive prices, short lead times, and the flexibility to realize both small series and large-scale production. With TOS, you choose a single partner who manages the entire casting process – from design to post-processing and assembly .

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Close-up van stalen spuitgietmatrijs in machine voor productie van metalen onderdelen bij TOS

Why choose TOS

Significant Cost Savings
Broad Network of Suppliers
European Quality Standards
Personal Dutch Contact Point
Expertise in Labor-intensive Processing
Aluminium spuitgietonderdelen direct na het gieten in de matrijs, onderdeel van het die casting proces bij TOS

What is high-pressure die casting and what options does TOS offer?

High-pressure die-casting is a modern and efficient production technique in which liquid metal is injected into a steel mold under very high pressure. The result is a casting with a precise shape, thin walls, and excellent dimensional accuracy. Thanks to the speed and repeatability of this process, high-pressure die-casting is ideally suited for larger production runs where consistency, precision, and detail are paramount.

A major advantage of high-pressure die casting is its ability to create complex shapes and fine details without requiring extensive post-processing. This allows companies to save time and money while maintaining high component quality. Furthermore, the technology allows products to be combined with specific post-processing techniques such as CNC machining or surface treatments, resulting in fully functional end products.

Aluminum and zinc alloys are primarily used in this process. Aluminum offers an excellent balance of low weight, high strength, and corrosion resistance, making it widely used for technical components and structural applications. Zinc alloys are distinguished by their high fluidity and precision. This makes them ideal for thin-walled or decorative products, where tight tolerances and a smooth surface are essential.

With high-pressure die casting at TOS, you benefit from an efficient, scalable, and reliable production method suitable for a wide range of industries.

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Precisie aluminium onderdeel uit spuitgietproces, vervaardigd via die casting bij TOS

How we work

First acquaintance

During this conversation we will briefly explain what we can do for you and answer your questions.

Price research

Based on your product and requirements, we request prices and delivery times from various suppliers.

Quotation and agreement

We will then prepare a clear quote. Prices are quoted based on your terms and conditions.

Prototype and approval

Once you have approved our proposal, we will start making a prototype.

Quality control and delivery

After approval of the prototype, the assignment will begin.

Materials and alloys for high-pressure die-casting

Pressure die casting is primarily used with aluminum and zinc alloys. Aluminum offers a strong combination of low weight, high strength, and good corrosion resistance, making it widely applicable in sectors such as automotive and mechanical engineering. Zinc alloys are distinguished by their high fluidity and precision. This makes them ideal for thin-walled products, complex shapes, and decorative applications. Moreover, zinc’s low melting temperature extends the life of the molds, making the process efficient and economically attractive for larger production runs. Overview of alloys for pressure die casting

Alloy Properties Strength Corrosion resistance Applications
AlSi9Cu3
Good fluidity, dimensionally stable, economical
Middle
Good
Automotive, mechanical engineering
AlSi10Mg
Strong and corrosion resistant
High
Zeer Very good
Constructions, machine parts
Zamak 3 (ZnAl4)
Excellent detail reproduction, easy to coat
Middle
Good
Precision mechanics, decorative parts
Zamak 5 (ZnAl4Cu1
Higher strength, good wear resistance
High
Good
Technical components, fasteners

Advantages and Disadvantages of Pressure Die Casting

  • High dimensional accuracy – Complex shapes with tight tolerances.
  • Smooth surface – Minimal post-processing required, often ready for immediate use.
  • Fast process – Suitable for medium to large series.
  • High initial costs – Molds and machines are expensive, especially cost-effective for larger series.
  • Limited material selection – Not all metals are suitable for pressure die-casting.

How we work on a high-pressure die casting project

At TOS, we employ a structured approach to every high-pressure die casting project. From initial consultation to final delivery, we ensure an efficient process with a focus on quality, cost, and delivery time. Thanks to our expertise in mold design, test castings, and series production, we can create complex parts with high precision. Below are the 10 steps we follow to successfully and reliably produce castings using high-pressure die casting.

Gestapelde aluminium spuitgietonderdelen na productie bij TOS, gereed voor nabehandeling of montage
In the first phase, we discuss the product’s application, required volumes, budget, and delivery times. This helps us determine whether high-pressure die casting is the most suitable production method and which approach best suits your project.

Our specialists review the design and provide Design for Manufacturing advice. This includes optimizing wall thicknesses, draft angles, and tolerances. We also advise on the right alloy, such as aluminum or zinc, to maximize the benefits of high-pressure die casting.

You’ll receive a transparent quote that includes both the mold costs and the unit price. We’ll also create a clear schedule, so you know exactly how long the high-pressure die casting project will take and when the first delivery will occur.
A precise mold is the key to successful series production. We design and manufacture high-pressure die casting molds that optimally match the geometry of your product and the chosen alloy. This forms the basis for a stable casting process. Often, before the molds are started, we print 3D models and offer them for inspection.
Before serial production begins, we perform a trial casting, or First Article Inspection. These initial products allow us to validate the high-pressure die-casting process and assess whether all specifications and tolerances are being met.
After the test casting, all feedback is incorporated. Once the product meets all requirements, we finalize the specifications in a design freeze. From this point, the high-pressure casting process continues without modification for series production.
We produce the desired quantities of castings according to drawings and quality standards. Thanks to the speed and repeatability of high-pressure casting, we can deliver large series with a high degree of detail and dimensional accuracy.

If desired, we perform CNC machining , such as milling, tapping, or drilling. This way, we combine the advantages of high-pressure die casting with precision machining, delivering a fully functional end product.

To give your castings extra protection or a high-quality appearance, we offer various treatments, such as powder coating , chrome plating , or E-coating. This makes a part produced via high-pressure die casting even more suitable for its application.

Each product is carefully inspected , both visually and dimensionally. We can provide certificates and reports upon request. Finally, we provide customized packaging and reliable delivery, ensuring your high-pressure die-casting components are ready for immediate use.

Cases

Sand Casting and Machining of Iron Wheels

For a client in the heavy transport sector, we produced an iron wheel for high-load trailers, sand-cast in GG25 gray....

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Gesmeed trekoog dat volledig CNC-verspaand is voor nauwkeurige passing.

Forged Towing Eyes for Earthmoving: Maximum Strength Through Precision Forging

For a client in the earthmoving sector, we produced a series of high-quality forged towing eyes. The heads of these....

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FAQ's

What is high-pressure die casting?
Pressure die casting is a process in which liquid metal is injected into a mold under high pressure. The result: precise and complex parts with a smooth surface.
At TOS we primarily work with aluminum and zinc alloys, each with specific advantages in strength, weight, and detail accuracy.

Yes. Parts can be CNC machined , for example, by milling, tapping, or drilling, so that they are fully tailored to your application.

High-pressure die casting is most cost-effective for medium to large series, but TOS can also produce smaller quantities for prototyping or pre-series production. Thanks to our international network, we offer flexible operations, ensuring you always find the right balance between quality, speed, and cost.

TOS manages the entire process: from design and mold production to casting, post-processing, and logistics . We offer competitive prices, short delivery times, and reliable quality .