Aluminum die casting

copperzincnon ferrous

Overview
Norck delivers precision die casting services for aluminum and other non‑ferrous alloys, producing components with complex geometries, tight dimensional control and repeatable surface finishes. Solutions cover prototype runs, pilot production and high‑volume manufacturing, with integrated tooling, machining and finishing options.

Applications / Industries

• Aerospace
• Defense
• Robotics
• Industrial equipment and machinery
• Automotive
• Electronics
• Energy
• Hardware and enclosures
• Consumer products

Capabilities

• Aluminum die casting and other non‑ferrous alloys (zinc, magnesium, copper, tin‑based)
• Flexible production volumes: prototypes, pilot runs, medium and high volumes
• Long‑life hardened steel tooling optimized for repeatability and throughput
• Secondary operations: precision CNC machining, plating, painting/coating, assembly
• Design for Manufacturability (DFM) and engineering support

What is Die Casting?
Die casting injects molten metal under high pressure into a hardened steel mold cavity to produce precise, repeatable parts. The process is cost‑effective for medium to high volumes and commonly uses non‑ferrous alloys for strength-to-weight and surface quality benefits.

Advantages of Die Casting

• High dimensional accuracy: typical tolerances on many features around ±0.05 mm; critical faces may require post‑machining
• Ability to produce complex shapes and thin walls with good repeatability
• Fast cycle times and consistent repeatability for volume production
• Reduced unit cost by minimizing machining and finishing steps in series production

Fabrication Process
Typical production flow:

• 1. Die preparation: apply mold lubricant and inspect cavities
• 2. Filling: inject molten alloy into closed die under pressure and hold until solidification
• 3. Ejection: open die and remove part using ejector system
• 4. Post-processing: remove gates/risers, trim, deburr, and perform required machining and surface treatments

Prototype & Development
Norck supports prototype aluminum die casting to validate form, fit and function before committing to production tooling. Rapid iterations and bridge tooling options help reduce time to market while assessing manufacturability and cost tradeoffs.

Norck Value Proposition

• Engineering-driven DFM reviews to optimize cost, weight and performance
• Integrated supply chain and partner network for scalable capacity
• End-to-end delivery: tooling, casting, machining and finishing
• Data-enabled process control to improve quality and traceability

Secondary Notes
Die‑cast parts often require secondary operations (tapping, machining, polishing, plating) to meet final functional and surface requirements. Early design alignment with die casting constraints minimizes rework and downstream cost.

Technical specifications / Features

• Typical tolerances: approx. ±0.05 mm (depends on geometry and material)
• Main materials: aluminum alloys (primary), zinc, magnesium, copper, tin‑based alloys
• Supported production: prototypes, pilot runs, medium and high‑volume series
• Tooling: hardened steel dies with long‑life options
• Available secondary processes: CNC machining, plating, painting/coating, assembly
• Engineering support: DFM reviews, alloy selection guidance, tooling recommendations
• Typical part capabilities: complex geometries, thin walls, integrated bosses and ribs, tight dimensional repeatability