Custom High Pressure Die Casting Manufacturer
The Federal Group USA provides custom high pressure die casting services for businesses requiring durable, high-volume near-net-shape components.
Since 1980, we have manufactured custom metal parts using advanced hot chamber and cold chamber die casting equipment. We produce metal components from specialized non-ferrous alloys, built to withstand extreme operating conditions while meeting strict tolerance requirements.
Request a QuoteWhy Choose TFG USA for High Pressure Die Casting
We provide comprehensive HPDC services to deliver complex, high-volume metal components with exceptional dimensional accuracy.
QMS 9001:2015 Certified
Our cross-functional quality inspections and dedicated material documentation verify that cast components align with rigorous built-to-print specifications.
Hot and Cold Chamber Equipment
We use advanced cold chamber and hot chamber die casting systems designed to efficiently process a wide range of non-ferrous alloys with high repeatability.
Comprehensive Secondary Operations
Beyond the initial injection and ejection phases, we perform precision CNC machining, tapping, and custom surface finishing entirely in-house.
Expert Engineering Set-Up Process
We conduct thorough engineering feasibility reviews and manage precise tooling configurations to minimize gas entrapment and maximize steel mold life.
Industries We Serve
We manufacture custom high pressure die cast components built to withstand the demanding environments of any heavy industry. The die casting process steps allow us to mass-produce durable parts for critical applications, so businesses receive consistent quality across large production runs.
Medical Industry
We produce complex diagnostic equipment parts and device housings that require strict adherence to dimensional tolerances and fine surface finishes.
Energy Industry
Our high pressure die casting process creates highly durable turbine housings, pipe flanges, and control panel enclosures designed for extreme operational stress.
Agriculture Industry
We cast high-strength gearbox housings, pump bodies, and bearing housings capable of enduring harsh agricultural conditions over long production lifecycles.
Processes and Technologies We Support
The high pressure die casting method involves four primary stages to produce accurate metal parts.
We start with mold preparation by applying a release agent, move to high-speed molten metal injection, hold the metal under pressure to accommodate solidification shrinkage, and finally execute part ejection using specialized ejector pins.
This controlled sequence helps us mass-produce complex geometries efficiently, and we support three distinct die casting technologies to match your specific material and volume requirements:
- Cold chamber die casting: Ideal for aluminum pressure die casting and high-volume runs requiring strength, using a separate furnace and shot sleeve for high melt temperatures.
- Hot chamber die casting: Best suited for zinc and magnesium, enabling exceptionally fast cycle times with the injection mechanism submerged directly in the molten metal.
- Multi-slide die casting: Enables rapid production of complex near-net-shape components, significantly reducing the need for extensive secondary operations.
High-Performance Machinery and Tooling
Our equipment operates with extreme injection and intensification pressures ranging from 10 to 175 MPa (1,500 to 25,000 psi). This high-velocity setup is designed to achieve complete mold filling in milliseconds. We secure our hardened steel dies with immense clamping force to maintain strict dimensional accuracy and ultra-thin wall thicknesses during the shot injection stage.
Processes of this type typically hold tolerances as tight as +/- 0.002 inches, and we can cast parts weighing from a few ounces up to 50 pounds. This rigorous process control allows us to produce consistent, high-strength components for demanding industrial applications.
High Pressure Die Casting Materials We Use
We carefully match specific non-ferrous metals to your application requirements to balance mechanical properties with manufacturability. TFG USA processes a distinct range of alloys to meet specific environmental and operational demands.
- Aluminum alloys: We process A380 for mechanical balance, A383 for intricate detail, A360 for maximum pressure tightness, and ADC12 for structural parts.
- Zinc alloys: These alloys deliver exceptional dimensional accuracy and smooth surface finishes for highly detailed components.
- Magnesium Alloys: This non-ferrous metal provides a high strength-to-weight ratio and excellent machinability for lightweight structural requirements.
Secondary Processes and Finishing Capabilities
After the core casting cycle, we follow this up with automated robotic extraction and controlled water quenching to stabilize the metal structure. We then perform precise flash removal using custom trim dies to prepare the part for final detailing.
Our comprehensive secondary operations include advanced CNC machining to achieve tight-tolerance features on complex geometries. We also apply customized surface treatments like anodizing, plating, and powder coating to enhance corrosion resistance and improve the final appearance of your components.
Partner With an Experienced Die Casting Manufacturer
Choose Federal Group USA for your next custom high pressure die casting project today.
- ▸9001:2015 Certified Quality Management System.
- ▸Manufacturing Facilities in the U.S., India & Taiwan.
- ▸Custom Metal Components for Medium- to High-Volume Production Since 1980.
