Tooling
Aluminum or steel die designed and CNC-machined to produce wax patterns.
★ Process Overview Die Casting
Die Casting
volume + speed.
High-pressure die casting (HPDC) injects molten alloy into a steel die at 100–200 MPa. Cycle times are 30–90 seconds, making it ideal for volumes from 10,000 to 1,000,000 parts per year.
Magnus operates a network of HPDC suppliers across Pune, Aurangabad and Coimbatore — with press capacity from 250-ton to 1,600-ton and full machining + finishing lines.
At a Glance
Tolerance
±0.05 – 0.15mm
Wall thickness
1.5mm – 12mm
Press range
250 – 1,600 ton
Cycle time
30 – 90 seconds
★ Specifications Process
Process
capabilities.
| Specification | Detail |
|---|---|
| Press range | 250 – 1,600 ton clamp force |
| Tolerance | ±0.05–0.15mm as-cast |
| Wall thickness | 1.5mm – 12mm |
| Materials | Aluminum (ADC10, ADC12, A380), zinc (Zamak 3/5), magnesium (AZ91) |
| Cycle time | 30 – 90 seconds per cycle |
| Tooling life | 100,000 – 500,000 shots |
★ Applications Industries we
Industries we
serve.
Automotive
Engine brackets, transmission housings, structural parts.
- Engine brackets
- Transmission housings
- Oil pans
- Steering components
Electrical & Electronics
Precision aluminum housings and zinc connector components.
- Motor housings
- LED heat sinks
- Connector bodies
- EMI shielding enclosures
Consumer
Hardware, appliances, kitchenware enclosures.
- Hardware fittings
- Appliance bodies
- Kitchen tools
- Electrical enclosures
Industrial
Pump housings, valve bodies, motor brackets.
- Pump housings
- Valve bodies
- Motor brackets
- Gearbox covers
Telecom & 5G
Aluminum and magnesium chassis for telecom infrastructure.
- Antenna housings
- RF enclosures
- 5G base station parts
- Heat-dissipating cases
Power Tools
Magnesium and aluminum housings for handheld power tools.
- Drill gear cases
- Saw housings
- Trimmer enclosures
- Mower components
★ The Investment Casting Process
Six steps from
Six steps from
wax to shipment.
An overview of how investment castings are produced at our partner foundries. Each step is monitored and documented for traceability.
Wax Pattern
Wax injected into die, assembled into a tree along a central runner.
Shell Building
Wax tree dipped repeatedly in ceramic slurry to build a hard shell.
Dewax & Fire
Shell heated to melt out wax, then fired to 950°C for strength.
Pour & Cool
Molten metal poured into shell. Cooled, shell broken, parts cut from tree.
Finish & QC
Grinding, heat treatment, machining, inspection, packaging, shipment.
★ Materials Alloys &
Alloys &
materials.
Aluminum Alloys
- ADC10 (LM2)
- ADC12 (LM24)
- A380
- AlSi9Cu3
- AlSi12
Zinc Alloys
- Zamak 3
- Zamak 5
- Zamak 7
- ZA-8
- ZA-27
Magnesium
- AZ91D
- AM60B
- AZ31B
★ Quality Control Four-stage
Four-stage
inspection.
inspection.
01
Material Cert
Spectro analysis on every heat; chemistry certified against grade specification.
02
Dimensional
CMM and 3D scanning at 100% of first-piece + AQL 1.0 across the lot.
03
Surface & visual
Magnetic particle / dye-penetrant for surface defects; 100% visual inspection.
04
Mechanical testing
Tensile, hardness, impact testing per ASTM/ISO standards on sampled parts.
★ Client Success
A US power tool brand's
A US power tool brand's
cost transformation.
A few of our favourite client wins from the last 24 months.
★ Power Tools · United States · 2025
$180k tooling investment recovered in 9 months.
A North American power tool OEM commissioned Magnus to set up dedicated aluminum die casting for cordless drill gear housings — 240,000 units per year across three SKUs. Magnus managed supplier selection, tooling design, parallel production, and the first 12 months of operations.
$2.4M
Saved · 3 years
38%
Cost reduction
99.7%
First-pass quality
★ FAQs
Questions buyers
ask us first.
What is the typical tooling cost?
Aluminum HPDC tooling: $15,000–$60,000 depending on part complexity, cavities, and slide count. Tooling is buyer-owned.
What is the break-even volume vs investment casting?
Roughly 8,000–20,000 pieces/yr in aluminum. Below that, investment casting often wins on total landed cost.
Can you supply finished + machined parts?
Yes. All suppliers in our network have integrated CNC machining and surface finishing (powder coat, anodise, chrome) lines.
Do you handle steel die-casting?
No. HPDC is limited to aluminum, zinc and magnesium. For steel parts, see Investment Casting or Forging.
★ Related Capabilities
Pair forging
Pair forging
with these processes.
★ Ready to Start? Start sourcing
Start sourcing
in 48 hours.
Share your specs. We come back with vetted suppliers, factory-direct pricing, and a sample timeline — at no cost.