Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, and tin based alloys, although ferrous metal die castings are possible. The die casting method is especially well suited for applications where a large quantity of small- to medium-sized parts requires accurate details, fine surface quality and dimensional consistency.
Excellent dimensional accuracy is dependent on the casting material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and 0.02 mm for each additional cm (0.002 in. for each additional inch)
Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm (0.030 n.)
Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.
A variety of metal alloys can be cast, with aluminum, zinc and stainless steel being the most common.