Top 10 List - Buyer FAQs for Aluminum Die Casting

GD CASTINGS TOP 10 LIST OF BUYER FAQs FOR ALUMINUM DIE CASTING

10. What sets you apart from overseas die casters?

While overseas suppliers may appear cheaper, our customers value us because:

•Shorter lead times and no transoceanic shipping risk

•Stronger IP protection and compliance with U.S. standards

•Consistent quality backed by ISO certification and PPAP

•Easier communication and local support in the same time zone

•Supplier consolidation — machining, inspection, and casting all under one roof

In short: we deliver faster, safer, and higher-quality parts with peace of mind that your supply chain is secure.

9. What industries do you serve, and what applications are you experienced in?

We serve a diverse range of industries, including:

•Automotive & Heavy Truck – hub caps, housings, brackets, and structural parts

•Lawn & Garden / Outdoor Power Equipment – engine covers, transmission housings

•Lighting & Electrical – enclosures, heatsinks, and junction housings

•Cookware / Home goods – handles, knobs, appliance housings

•Industrial Valves & Controls – pressure-tight valve bodies, housings

•Healthcare Devices – precision components requiring high consistency

This diversity makes us resilient and gives us a broad knowledge base to apply best practices across industries.

8. Can you help with design for manufacturability (DFM)?

Yes — we regularly work with OEMs and engineers during the design stage. Our team provides DFM feedback, MAGMA flow simulation, and cost-saving recommendations. This helps reduce weight, eliminate unnecessary machining, extend tool life, and lower overall piece price before tooling is built.

7. How long does die casting tooling last?

Typical die casting tooling lasts 100,000–300,000 shots, depending on alloy, part geometry, and tool maintenance. We track every tool in our system and provide lifetime management, ensuring preventative maintenance and repairs are done to maximize life and performance.

6. What are the cost drivers in aluminum die casting?

The main factors that affect part cost include:

•Tooling investment (single vs. multi-cavity, complexity, lifetime requirements)

•Part complexity (thin walls, undercuts, tight tolerances)

•Alloy choice (different alloys vary in price and machine wear)

•Secondary machining/finishing requirements

•Annual production volume (higher volumes lower piece price)

We’re transparent about cost drivers and will work with you on design for cost savings.

5. How do you ensure quality and consistency in die cast parts?

Quality is built into every step of our process:

•ISO 9001:2015 certified systems

•PPAP, APQP, and DFM support for new programs

•CMM inspection and X-ray testing for dimensional accuracy and internal integrity

•SPC monitoring during production to maintain consistency

We provide full documentation packages upon request to meet customer and industry standards.

4. What secondary processes do you provide in-house?

We offer a full range of value-added services to minimize supplier handoffs:

•CNC machining (25+ machining centers)

•Deburring and finishing

•Leak and pressure testing

•Powder coating and painting (via partners)

•Assembly services

By keeping machining and inspection in-house, we control quality and lead times from casting through final shipment.

3. What part sizes and machine tonnages can you accommodate?

Our two facilities operate 30+ cold chamber die casting machines ranging from 600T to 1200T. This allows us to produce parts from a few ounces up to 20+ pounds in weight. If you’re unsure whether your part fits, simply send us your CAD model and we’ll quickly confirm tonnage and feasibility.

2. What alloys do you run, and how do I choose the right one for my application?

We regularly cast aluminum alloys 360, 380, 383, 413, and B390. Each has unique strengths:

•360 – Excellent corrosion resistance; great for outdoor use.

•380 – General-purpose alloy; balances strength, cost, and machinability.

•383 – Similar to 380 but with improved resistance to corrosion and wear.

•413 – Superior pressure tightness; ideal for hydraulic components.

•B390 – Very high wear resistance; used in engine and heavy-duty applications.

Our engineers will recommend the best alloy based on your application’s strength, corrosion, weight, and thermal requirements.

1. What is the typical lead time for new die cast tooling and production?

New die cast tooling typically takes 12–16 weeks from design approval to first sample parts. This includes tool design, build, and validation. Once tooling is complete, we run sampling and PPAPs (Production Part Approval Process) to confirm quality. From there, production ramp-up is usually 2–4 weeks, depending on machining and finishing needs. Repeat orders from existing tools can often be shipped in just 2–3 weeks.