Custom Die Casting Services

There is no “one-size-fits-all” price in die casting. The total cost of your project depends on four key drivers:

• Tooling (the mold) – the upfront investment that defines your part’s geometry
• Material volume – alloy type, shot weight, and scrap rate
• Part complexity – undercuts, threads, inserts, and dimensional tolerances
• Production quantity – higher volumes dramatically lower per‑part cost
• Production Volume – Tooling and setup costs are amortized over every part you cast. Going from 1,000 to 100,000 units can cut your unit price by 50–80%.

Complexity – Features like thin walls (≤1mm), tight tolerances (±0.01mm), or internal cavities add to design, mold construction, and cycle time.

• High‑Speed Production – Ideal for scaling from pilot runs (hundreds) to mass production (millions) with cycle times as low as a few seconds.

• Superior Surface Finish – Parts come out smooth and consistent, often ready for plating, painting, or direct retail assembly.

• Tight Tolerances – FERR holds dimensions up to ±0.01mm, eliminating secondary machining on most features.

• Complex Geometries – Combine multiple components into one single cast part — reduce assembly cost and improve reliability.

Porosity is the #1 enemy of pressure‑tight and high‑strength die cast components. At FERR, we attack it with a proven four‑layer defense:

1. Vacuum‑assisted die casting – We evacuate air from the shot sleeve and cavity before injection, dramatically reducing gas entrapment.
2. Optimized gating & overflow design – Our flow simulations (Magma/Flow‑3D) ensure laminar filling and trap air away from critical zones.
3. Precise process control – Real‑time monitoring of plunger speed, intensification pressure, and metal temperature to avoid turbulence.
4. Post‑cast quality validation – X‑ray and CT inspection on sample lots to verify internal integrity, plus optional impregnation sealing for pressure‑tight applications.

When designing parts for die casting, several key considerations must be addressed to ensure optimal performance, manufacturability, and cost efficiency. At FERR, our engineering team works with you from the design phase to avoid common pitfalls and optimize for production.

• Wall Thickness – Maintain uniform wall thickness to promote even cooling and solidification, reducing the risk of warping, sink marks, or internal stresses. Thinner walls are preferred for faster cycle times and material savings, but feasibility depends on the alloy and part geometry. FERR can produce walls as thin as 0.5 mm in zinc and 1 mm in aluminum/magnesium.

• Draft Angles – Include draft angles to ensure easy ejection of the casting from the die without damaging the surface or the mold. A minimum draft angle of 1° to 2° is recommended for external walls, and up to 3° for internal cavities, depending on the depth and surface finish requirements.

• Fillets and Radii – Use fillets and radii at all internal and external corners to eliminate sharp edges, which can cause stress concentrations and crack initiation. Proper radii also improve molten metal flow, reduce turbulence, and extend die life.

• Gating System – Design an efficient gating system to guide molten metal into the cavity with minimal turbulence and air entrapment. FERR uses advanced flow simulation (Magma/Flow‑3D) to optimize gate location, runner design, and overflow placement for each part.

• Venting – Proper venting is essential to allow air and gases to escape from the mold cavity during injection. Inadequate venting leads to porosity, cold shuts, or incomplete filling. FERR integrates precision vents and vacuum-assist options for porosity-sensitive components.

• Simplifying Geometry – Simplify part geometry where possible to avoid undercuts, slides, or complex core pulls that increase tooling cost and cycle time. When undercuts are unavoidable, FERR’s tooling engineers can propose cost-effective side-action designs.

Yes. Post-machining of die cast parts is not only possible but often necessary to achieve tighter tolerances, smoother surfaces, or features that cannot be cast directly. At FERR, we offer in-house CNC machining, drilling, tapping, milling, and turning as secondary operations.

Why post-machine at FERR?

• Achieve tolerances beyond ±0.01mm for critical mating surfaces

• Add fine details like small holes, threads, or undercuts

• Correct minor cosmetic imperfections or localized porosity

• Prepare surfaces for plating, painting, or assembly

By combining die casting with precision post-machining, FERR delivers the best of both worlds: the high-speed, near‑net shape of casting, and the accuracy of CNC machining for your most demanding dimensions.