Thin Wall Die Castings
Castings with 1.2–2.0 mm walls for weight-critical housings, using high-fluidity alloys.
Thin walls are a filling problem before they are a strength problem: the metal has to reach the far end before it freezes. We choose the alloy and gate position for fill first.
6–9 weeks
500 pieces
ISO 9001:2015 · IATF 16949
Technical Specifications
| Parameter | Value | Unit |
|---|---|---|
| Minimum wall | 1.2 | mm |
| Max part size | 400 × 300 × 100 | mm |
| Draft | 1–1.5 | ° |
| Ejection | Extra ejector layout | note |
| Porosity risk | Higher at 1.2 mm | note |
| Alloy | High-fluidity grades | required |
Available Materials
- AlSi12 (best fluidity)
- AlSi10Mg
- AZ91D (magnesium)
Typical Applications
- Weight-critical housings
- Consumer electronics frames
- Automotive structural parts
- Drone chassis
- Portable tool housings
Surface Finishes
- As-cast
- Shot blast
- Anodise
- Chromate conversion
- Powder coat
Industries Served
- Automotive & EV
- Consumer Electronics
- Aerospace
- Defence
- Robotics
What drives the price of this part
Derived from the callouts on this page. Where a driver is not on the drawing, it is not on this list.
- Part size
- Minimum wall at 1.2 mm decides which machine the part lands on and how many setups it needs. Size is the driver buyers most often leave out of a first enquiry, and it is the one that changes the quote fastest.
- Material
- The first material listed, Magnesium Alloy AZ91D (die casting), rates 8/10 on our machinability scale at 65–75 HB. On this shop's scale a harder alloy means slower passes and more tool changes, and that is cycle time the quote has to carry.
- Order size
- Minimum order is 500 pieces, where setup and tooling are amortised across the batch and per-part cost settles around cycle time and material. Below that quantity the same part costs more per piece, not less.
See how cycle time is calculated in the machining time calculator and what else moves a price in the cost driver reference.
How these parts are inspected
Matched to the callouts above and the instruments actually on the floor.
- Coordinate measuring machine (Zeiss CONTURA G2, two machines, GR&R 8.4% on the critical feature)
- Dimensional report against the drawing, with a 100% check on critical features rather than a sample
- Certificate of conformance and the mill certificate with every shipment
- First article inspection to AS9102, because this family carries an aerospace or automotive certificate
The full equipment list, with counts, is on the capability page; the inspection sequence is on quality and inspection.
Questions buyers ask
- How thin can a die casting actually go?
- 1.2 mm over a small area, 1.5–2.0 mm over anything long. Thinner than that the metal freezes before it fills the far end, and you get a short shot rather than a thin wall.
Related part families
Magnesium Die Cast Parts
Magnesium castings 30% lighter than aluminium, for housings where weight is the constraint.
Heat Sink Castings
Cast heat sinks with tall thin fins, for electronics that need volume rather than a machined block.
Aluminium Die Cast Housings
High-pressure aluminium housings from 0.5–15 kg, trimmed, machined and sealed-face checked in-house.