High Pressure Aluminum Die Casting and Low Pressure Aluminum Die Casting

This article tells you what is high-pressure aluminum die-casting and low-pressure aluminum die-casting, their differences, and how to choose.

Die casting machine

What is High Pressure Aluminum Die Casting?

High-pressure aluminum die casting is a die-casting process where molten aluminum is injected into a steel mold at high pressure. It produces intricate and precise aluminum components with tight tolerances.

Advantages of High-Pressure Die Casting

  1. Achieves excellent dimensional accuracy.
  2. Enables high production efficiency.
  3. It provides a good surface finish on castings.
  4. Allows for the production of thin-walled parts.
  5. Offers versatility in the choice of aluminum alloys.

Disadvantages of High-Pressure Die Casting

  1. Requires significant investment in equipment and tooling.
  2. Limited in the size of parts that can be produced.
  3. This may result in porosity issues in the castings.

What is Low Pressure Aluminum Die Casting?

Low-pressure aluminum die casting is a casting process that uses low air pressure to draw molten aluminum into a mold cavity.

Advantages of Low-Pressure Die Casting

  1. Minimizes porosity in castings, improving their mechanical properties.
  2. Enhances the integrity and structural strength of the produced parts.

Disadvantages of Low-Pressure Die Casting

  1. Longer cycle times compared to high-pressure die casting.
  2. It may require additional post-processing operations.
Die casting process

How to choose these two die casting methods

Choose high pressure

  • Parts requiring high dimensional accuracy and intricate details.
  • High-volume production requirements.
  • Need for a good surface finish on castings.
  • Thin-walled part designs.
  • Versatility in the selection of aluminum alloys.

Choose low pressure

  • More significant aluminum components with good surface finishes.
  • Parts that require reduced porosity and improved mechanical properties.


High pressure aluminum die casting and low pressure aluminum die casting are two distinct manufacturing processes used to produce aluminum components.

High pressure die casting involves injecting molten aluminum into a steel mold under high pressure. low pressure die casting utilizes low air pressure to draw molten aluminum into a mold.

Choosing the appropriate casting process depends on specific requirements. High pressure die casting is preferred for accurate, intricate components, high-volume production, good surface finish, thin-walled parts, and various aluminum alloys. Low pressure die casting is s uitable for larger components that require good surface finishes and improved mechanical properties.

Understanding the differences and advantages of each process allows manufacturers to make informed decisions when selecting the most appropriate casting method for their specific needs.

This article was first published on June 1, 2023

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