Custom Die Casting Company
At The Federal Group USA, we’ve provided custom die casting services for high-quality components since 1980. We offer a wide range of metal capabilities, including aluminum, zinc, and magnesium to manufacture everything from industrial gears and housings to valve bodies and electronic devices.
Request a QuoteDiverse Materials
Aluminum, magnesium, and zinc die casting capabilities.
Secondary Services
CNC machining, heat treatment, coating, plating, and more.
Precision Engineering
Complex die designs optimized for tight tolerances and custom parts.
Advanced Technology
Hot chamber, cold chamber, vacuum, and squeeze die casting processes available.
Die Casting Case Study
A leading manufacturer approached The Federal Group to provide aluminum die casting services for a part that could be used “as cast”—without further machining—while ensuring leak-free assembly.
Diverse Sectors We Serve
The custom die casting solutions offered by The Federal Group USA serve a wide range of industries, from electronics to industrial equipment.
Electronics and Power Systems
Our aluminum and zinc die castings are ideal for housings, heat sinks, and connectors for electrical components. For reliable performance in demanding applications, these lightweight components deliver excellent conductivity and efficient thermal management.
Industrial Equipment and Automation
Die casting from TFG USA provides the robotics, machinery, and automation industries with components that are strong, reliable, and producible at scale. Using lightweight materials, elements such as gear housings and brackets are die cast to maximize cycle efficiency and maintain consistent performance.
Consumer and Commercial Products
TFG’s aluminum and zinc die-cast parts are used in lighting, appliances, and hardware, delivering both durability and aesthetic appeal. With various finish options, including powder coating and anodizing, our parts are supplied with high-quality surface finishes for consumer-facing designs.
Our Die Casting Capabilities and Methods
At The Federal Group, we offer diverse custom die casting manufacturing capabilities, using both high-pressure and gravity die casting with cold-chamber and hot-chamber processes. Hot chamber machines efficiently handle zinc and lower-melting-point alloys, while cold chamber machines are used for aluminum and other higher-melting-point metals. With 600, 800, and 1200-ton machines, our capabilities support fast cycle times for various geometries and sizes.
Tooling is designed for durability, so even with high-volume production, our die casting processes deliver precise results for demanding industrial applications, robotics, and automation systems. We cast everything from electronic housings and manufacturing brackets to industrial equipment and enclosures. Advanced automation and process monitoring systems ensure tight tolerances and repeatable results.
Materials and Alloy Options
Custom die casting manufacturing typically uses non-ferrous alloy materials because it has high dimensional stability. The four most commonly used alloys for die casting are aluminum, magnesium alloys, zinc, and copper.
The choice of die castings materials is influenced by several factors such as density, melting point, strength, resistance to corrosion, and cost. The material also influences the type of machine used.
- Aluminum (A360, A380, ADC12): High strength-to-weight ratio, excellent thermal conductivity, good corrosion resistance, easy to machine. Commonly used for housings, enclosures, and industrial components.
- Magnesium alloys: Very high strength-to-weight ratio, good thermal conductivity, moderate corrosion resistance, lightweight, and suitable for thin-walled parts. Often used in robotics, portable equipment, and complex geometries.
- Zinc: Moderate strength, medium thermal conductivity, fair corrosion resistance, very machineable with a superior surface finish. Ideal for consumer products and intricate components.
- Copper: High strength, excellent thermal conductivity, good corrosion resistance, more challenging to machine with a higher cost. Best for electrical connectors and specialty components.
Finishing and Value-Add Services
As a premier custom die casting company, our die cast components can be delivered ready for assembly, thanks to a full range of finishing and value-added services. Our custom die casting solutions include finishing and secondary CNC machining services, deburring, drilling, threading, and a variety of inspections to ensure material integrity, dimensional accuracy, and consistency.
We also offer a variety of surface finishing options, such as plating, painting, anodizing, and powder coating. With the right finishes, components are more durable, corrosion-resistant, and aesthetically appealing. With our finishing services, die cast components look great and perform reliably.
Quality Control and Risk Mitigation
At The Federal Group USA, quality control is integrated into every stage of our die casting process. Our team uses advanced metrology equipment, CMM inspection, and statistical process control (SPC) to verify precision and consistency.
Upon request, each part undergoes first-article inspection, material certification, PPAP submissions, and final audits to ensure it meets exact specifications. This disciplined approach minimizes risk, reduces defects, and guarantees reliable, repeatable performance for every die-cast component we produce.
Is Die Casting Right for Your Project?
Die casting is ideal for projects that require high-volume casting production and precise dimensions, but it may not be the best fit for every project. The high initial die cast tooling and mold costs mean that this method is best suited for parts produced repeatedly, such as in large production runs, or for parts with complex geometries.
Consider die casting if your project involves:
- High-Volume Production: Die casting is economical when casting hundreds or thousands of parts.
- Tight Tolerances: Ensures precise dimensions and repeatable results.
- Complex Shapes: Supports intricate designs and thin walls.
- Heat Dissipation: Aluminum die castings provide excellent thermal management and durability.
For projects with low volumes, simpler geometries, and less precise tolerances, The Federal Group offers a wide range of metal casting options, including sand casting and investment casting services. Extremely large or heavy parts may also require these alternative casting methods. Metal stamping and forging may be a better fit. With TFG’s custom die casting manufacturing, you can rely on the right solution based on part geometry, size, and mechanical properties.
Start a Die Casting Project Today
Whether your project requires complex shapes, multiple components, high dimensional accuracy, or corrosion resistance, we have the best casting method for you. The Federal Group USA has been a leader in the die casting industry for more than 40 years.
To learn more about our custom die casting processes or to receive a quote for your project, contact us today.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
