Step 01
DFM and die design
We review your 3D model for draft, wall thickness, fillet radii, parting line and gating, and propose changes that reduce porosity and machining.
Core Service · Thirumudivakkam, Chennai
Aluminium Die Casting Services
from Tooling to Dispatch
We cast aluminium components on cold-chamber high-pressure die casting cells at our Thirumudivakkam plant — from die design and sampling through trimming, machining, inspection and dispatch to your assembly line.
- Process
- Cold-chamber HPDC
- Machine range
- 250T – 350T
- Alloys
- ADC12 · AC14 · A380 · LM24 · LM6
- Location
- Thirumudivakkam, Chennai
What aluminium die casting is — and when it is the right process
Aluminium die casting forces molten aluminium alloy into a hardened steel die under high pressure. The metal fills thin sections in milliseconds and solidifies against the cooled die steel, producing a near-net-shape part with good surface finish, tight repeatability and fine as-cast detail such as ribs, bosses and cored holes.
It is the most economical route when you need medium to high annual volumes of the same geometry: tooling is a one-time investment, while cycle times are measured in seconds. For low volumes or very large, thick-walled parts, gravity or sand casting may be more suitable — our engineers will tell you honestly during the RFQ review.
At Sunmax, every programme runs through the same controlled route: DFM review, die design, alloy melting and degassing, injection, controlled cooling, trimming, secondary operations and inspection — documented for traceability.
Process
Our aluminium die casting process
Each step has its own checks so that a defect is caught where it originates, not at final inspection.
Step 02
Melting and alloy control
Certified ingots are melted and held in Silcarb furnaces at a controlled 685°C ± 5°C, then degassed before transfer.
Step 03
Injection
Metal is ladled into the shot sleeve and injected into the clamped die; shot speed and intensification pressure are set per part.
Step 04
Solidification and ejection
Die cooling channels control solidification; the part is extracted and the die is sprayed for the next shot.
Step 05
Trimming and finishing
Runners, overflows and flash are removed; parts are shot blasted, deburred or linished as specified.
Step 06
Machining, inspection and dispatch
Critical features are machined and gauged, then parts are packed to your specification and dispatched.
Capabilities
Technical capabilities
Figures below are our current plant capabilities. Ask us about parts outside these ranges.
| Die casting machines | 250T Zitai · 350T Toshiba |
|---|---|
| Maximum shot weight | 3.5 kg aluminium (350T cell) |
| Part weight range | 2.3 kg – 3.0 kg |
| Maximum part envelope | [INSERT MAX PART SIZE, mm] |
| Minimum wall thickness | [INSERT TYPICAL MIN WALL, mm] |
| Annual capacity | 840 K |
| Secondary operations | Trimming, shot blasting, deburring, linishing, drilling & tapping, CNC machining |
Aluminium alloys we cast
Alloy choice balances fluidity, strength, ductility, pressure tightness and thermal conductivity. See the full property table on our components page.
- ADC12 (JIS)
- High fluidity — the general-purpose automotive alloy
- A380 (ASTM)
- Good strength and castability for housings
- AlSi9Cu3 (EN AC-46000)
- European equivalent for structural housings
- AlSi10Mg
- Better ductility for thin walls and heat-sink fins
- LM24 (BS 1490)
- Common UK/Indian specification for pressure die castings
Typical aluminium die cast components
Parts we are typically asked to quote:
- Transmission and gearbox housings, covers and end-shields
- Motor housings, stator frames and rotor end-rings
- Brackets and engine / powertrain mounts
- Pump bodies, impeller housings and valve manifolds
- Electrical enclosures, switchgear covers and lighting housings
- Heat sinks and inverter housings
Industries
Industries we supply with aluminium die casting
Automotive
Transmission housings, brackets, mounts and covers for OEM and Tier-1 lines.
Electric Vehicles
Motor housings, cooling jackets and enclosures for EV drivetrains and batteries.
Electrical & Electronics
Enclosures, switchgear covers, heat sinks and lighting housings.
Industrial Machinery & Pumps
Pump bodies, hydraulic manifolds, gearbox end-shields and flanges.
- Spectrometer check of melt chemistry before pouring
- First-article dimensional inspection on CMM
- Porosity checks on critical sections
- In-process gauging of machined features
- Batch traceability from heat to dispatch
FAQ
Aluminium Die Casting — frequently asked questions
What volumes make aluminium die casting economical?
Die casting suits repeat production because the die is a one-time cost and cycle times are short. As a guide it becomes economical from a few thousand parts per year upwards; we confirm the break-even for your part during the RFQ review.
Which aluminium alloy should I choose?
ADC12 or A380 suit most housings and brackets. AlSi10Mg is preferred for thin walls, better ductility or heat sinks. Share your functional requirements and we will recommend a grade.
Do you make the die casting tool?
Yes. We carry out DFM, die design and tool development, and maintain dies in our own toolroom. You can also supply an existing tool for evaluation.
Can you supply machined, ready-to-assemble parts?
Yes. We machine, deburr and inspect castings so they can go straight to your assembly line.
What do you need to quote?
A 3D model (STEP/IGES) or 2D drawing, the alloy, annual quantity and any critical tolerances or leak-test requirements. Use our request-a-quote form to upload drawings.
Related capabilities
Request for Quotation
Get a quote for aluminium die casting
Share your 3D model or drawing, alloy and annual quantity. Our engineering team reviews every enquiry for manufacturability before quoting.