Case Study on Aluminum Die Casting

A customer who was looking for aluminum die casting process approached CFS Foundry, stating that they were using the aluminum die casting parts with no extra machining. As a result, the part that fit perfectly leaked and would be loose during assembly. However, thanks to our team of die casting experts, the problem was solved quickly. They analyzed that if the parts are designed according to the usage, they may show problems against the casting tolerance. After investigating, our experts created a list of suggestions that you can see in below.

Case Study on Aluminum Die Casting


To create the specified part, our aluminum foundry compiled a list of several elements that needed to be taken into account to achieve successful results. One of those considerations was that it is necessary to overmold the part to hold the electrical connections in place. Furthermore, our experts determined that for injecting the overmolding, it is required to seal off high tolerance areas within the piece. Also, the process must be done in a fashion that seals the parts together with precise measurements.


After the team identified the challenges, they evaluated things that would help them to overcome this problem. Finally, they concluded that the standard tolerance for aluminum die casting of the part was CT6. However, the tolerance was beyond most of the critical tolerances designed for the part.

Based on this, our experts started experimenting by adding interior drafts into the design and drawings of the parts as it may solve the tolerance difference problems. Upon further analysis, it became apparent that the overmold tooling, which was required to be entirely leak-proof during the injection process, should not be manufactured until the design and modifications to the part were complete.


Our team did an excellent job; based on the analysis, challenges, and customer collaboration, our experts, concluded different solutions regarding machining, tooling, and the overall part. First, they specified that the sealing surfaces and mating parts where the surfaces meet would require specified tolerance machining.

Second, our experts advised that it is necessary to redesign the part as it will allow the draft in the inner walls to release the part from the die. After that, the draft should be machined to make the walls tolerance competent for the overmolding tooling.

Finally, as predicted, our team faced problems while measuring the parts because of the part set-up and datum. To solve this problem, the experts estimated it with CMM and verified the dimensions by 3D scanning.

Contact CFS Foundry

If you have quality issues with your current aluminum die casting or aluminum gravity casting project, contact CFS Foundry to solve the issues for you!

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