High-pressure aluminum, zinc, and magnesium die casting from India. Presses up to 500 tons, ±0.1mm tolerance, near-net-shape parts with excellent surface finish. IATF 16949-certified suppliers for automotive Tier-1s, consumer electronics, and industrial OEMs across 30+ countries.
Die casting forces molten non-ferrous metal — primarily aluminum, zinc, or magnesium — into reusable steel dies at high pressure. The result: thin-walled, dimensionally precise, near-net-shape parts at production rates that no other casting process can match.
Magnus partners with 45+ IATF 16949 and ISO 9001 certified Indian die casters operating presses from 50 tons to 1,300 tons. We've shipped over 12 million die-cast components across automotive, electrical enclosures, consumer hardware, and industrial machinery — from 5-gram zinc fittings to 10-kilogram aluminum housings.
Die casting's cost-per-part drops dramatically at volume because the high tooling investment amortises across hundreds of thousands of cycles. Tools commonly last 100,000 to 500,000 shots before replacement — making die casting the right answer when annual volumes exceed 5,000-10,000 parts.
| Parameter | Specification |
|---|---|
| Casting weight range | 5 grams to 10 kilograms (single piece) |
| Press tonnage range | 50T, 120T, 250T, 400T, 650T, 800T, 1,300T (HPDC machines) |
| Dimensional tolerance | ±0.1mm per 25mm length (ISO 8062 grade DCTG 4-5) |
| Surface finish (as-cast) | 1.5–3.0 μm Ra |
| Minimum wall thickness | 0.8mm (Mg), 1.0mm (Al), 0.6mm (Zn) |
| Aluminum alloys | ADC-12A380A383A413A360LM6LM24 |
| Zinc alloys | Zamak 3Zamak 5Zamak 7ZA-8ZA-27 |
| Magnesium alloys | AZ91DAM60BAM50AAS41B |
| Secondary operations | CNC machining, trimming, deburring, powder coating, anodising, e-coating, painting, plating, assembly |
| Quality standards | ISO 9001:2015, IATF 16949 (automotive), ISO 14001, RoHS, REACH |
| Testing | CMM dimensional, X-ray porosity, leak testing, pressure testing, spectrometer, salt spray, hardness |
High-volume parts where thin walls, near-net-shape, and consistency matter — these are die casting's home turf.
Engine, transmission, and structural die-cast components for Tier-1s.
Precision aluminum housings and zinc connector components.
Plumbing, hardware, and durable goods at retail scale.
Pump housings, gearbox cases, and machine sub-assemblies.
Aluminum and magnesium chassis for telecom infrastructure.
Magnesium and aluminum housings for handheld power tools.
High-pressure die casting (HPDC) is a fully automated cycle. Each step is closely monitored for quality and process control.
H13 steel die designed with cooling channels, ejector pins, gating system.
Hardened steel die CNC-machined, polished, heat-treated — 6-10 weeks.
Alloy ingot melted in dedicated furnace, degassed, temperature stabilised.
Molten metal forced into die at 70-200 MPa pressure in milliseconds.
Part cooled, ejected, runners trimmed off, flash deburred.
CNC machining, surface treatment, inspection, packaging, shipment.
Material traceability documented from ingot lot to finished part. Mill test certificates issued with every shipment.
Die casting's automated nature means defects (porosity, cold shuts, flash) appear in predictable ways. Magnus inspectors know exactly where to look.
Die FAI (First Article Inspection), cooling validation, gating analysis, X-ray porosity check.
Real-time monitoring of injection pressure, temperature, cycle time; SPC charts maintained per shift.
AQL 1.0/2.5 inspection: CMM dimensional, X-ray porosity, leak/pressure testing, surface finish, packaging.
Complete pack: PPAP, CoC, mill certs, FAI, dimensional report, PFMEA, control plan — all before container leaves port.
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.
Share your drawings and target volume. We'll come back with 3-5 vetted die casters, factory-direct pricing, and tooling timeline — at no cost.