Custom Die Casting Services
We are a US-based die casting company known for making high-quality components since 1980. TFG USA offers 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 high pressure 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.
Industries We Serve
The top die casting solutions offered by TFG USA serve a wide range of industries, from electronics to industrial equipment.
Electronics and Power Systems
For reliable performance in demanding applications, these lightweight die casting parts 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 for industrial equipment industries.
Consumer and Commercial Products
TFG’s aluminum and zinc die-casting 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.
Die Casting Capabilities and Processes
The Federal Group USA offers a range of custom die casting capabilities to manufacture precision metal components for industrial, commercial, and electronic applications. Our capabilities include multiple casting methods and process variations to accommodate different materials, part geometries, dimensional requirements, and production volumes.
Our die casting capabilities include:
- Gravity Die Casting: Uses gravity to fill a reusable mold, making it suitable for components requiring good mechanical properties and consistent dimensional accuracy.
- High Pressure Die Casting: Injects molten metal into a die at high pressure to produce complex, thin-walled components with excellent repeatability for high-volume production.
- Cold Chamber Die Casting: Commonly used for aluminum and other higher-melting-point alloys, including applications requiring lightweight, structurally sound components.
- Hot Chamber Die Casting: Offers rapid production cycles for suitable lower-melting-point alloys, particularly zinc, and is well suited to high-volume production of intricate components.
Depending on project requirements, additional die casting process options may include vacuum-assisted die casting and squeeze casting.
Die Casting Machinery and Technology
TFG USA’s manufacturing facilities are equipped with 600, 800, and 1,200-ton die casting machines to support a range of component sizes and production volumes. Available equipment and machine configurations vary by facility and material, including hot chamber and cold chamber systems. Tooling, automated handling, and process monitoring are selected based on part geometry, alloy requirements, and production targets to support consistent, repeatable manufacturing.
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. Learn more about our magnesium die casting capabilities.
- 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 manufacturer, 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 solutions 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 since 1980, and can assist you both as a reliable manufacturer and die casting supplier.
To learn more about our custom die casting processes or to receive a quote for your project, contact us today.
