Designed a metal product that requires manufacturing? Have you shortlisted die casting as a potential production method but are unsure about the die casting cost for making parts?
Some experts suggest that it is expensive, likely due to the equipment and additional tooling required. Yet, others argue that for large-scale productions, the process becomes more economical than CNC machining. Indeed, there is some truth to both viewpoints. But, how should you decide?
This article breaks down the costs involved in die casting a part, discussing all the factors that come into play and comparing it to modern CNC machining. We will also explore whether it’s more sensible to invest in a die casting machine or outsource product-making to a service provider.
What’s Die Casting?
Die casting is a manufacturing process that mainly produces non-ferrous metal parts (e.g., aluminum, zinc, and magnesium alloys). Ferrous metals like gray and ductile iron can be technically cast but the process isn’t widely practiced as higher melting points of these melts shorten mold’s life.
Die casting uses reusable, high-precision metal molds (dies) – so it’s classified as a permanent mold casting technique.
In this process, the molten metal gets poured/injected into the die casting mold under high pressure (upto 350 MPa). Casting under high pressure and the use of permanent molds is what distinguishes this process from other casting methods.
Advantages
- Higher production rates compared to CNC machining.
- Good surface finishing compared to other casting techniques.
- Thin sections (up to 0.5mm) can be made.
- Small grain and higher strength parts can be made.
- Longer mold and equipment life
Limitations
- Works best on non-ferrous metals.
- High initial costs for dies make it economically non-feasible for small production volumes.
What Factors Influence Die Casting Cost?
The cost of casting metal parts with die tooling depends on multiple factors, including the materials involved, production volume, tooling requirements, part complexity, and surface finish specifications.
This section shares how each of the factors contributes to the die cast cost. So, your design choices must be made after weighing in all these factors.
Material Costs
Two types of material costs come into play: one for the mold itself and another for the part being cast. The mold is typically made from hardened tool steel like H13, which can handle high-pressure cycles but costs more upfront.
Whereas, the cast material can be any non-ferrous – there is Aluminum die casting, zinc die casting, lead, and magnesium die casting – all these have different material rates and applications. You can further explore the difference in properties and use cases of in our zinc vs aluminum die casting post.
Production Volume
Die casting is built for bulk production, for a batch of a few hundred or thousands. The die-casting equipment is costly, and so are the permanent molds. However, if you’re making large batches, that initial investment gets spread out, which lowers the overall cost per part.
Tooling Costs
A lot of tooling and operations are involved in the process. The machine costs itself, the material for making the molds, and then the operational costs (CNC machining, EDM, or other process) in making the mold, all add a lot of expense initially. The biggest cost chunk here is making the permanent die, which most other processes don’t necessarily require.
Part Complexity
It’s natural for a geometry to raise the costs. Simple geometries (like flat panels or uniform shapes) are simple to cast and keep costs low. But complexity adds up quickly. For example, die casting components with thin walls, deep ribs, or internal threads require intricate die designs and precise cooling to avoid defects. Undercut – features that prevent the part from being ejected straight out of the mold – force engineers to add moving components to the die, which adds up costs.
Surface Finish Requirements
A basic “as-cast” finish, slightly rough but functional, is the most affordable option. If your part needs a polished look or a custom texture, the dies must be finely machined or treated, which adds to die cast tooling costs. For very smooth surface finishes, a secondary finishing process may be added, which also comes at a higher cost.
Lead Times
Standard lead times give manufacturers room to optimize die design, test prototypes, and schedule production efficiently. Rushing the process, let’s say, demanding a die in half the usual time, often means paying premiums for overtime labor or expedited shipping.
Die Cast Mold Cost Analysis
The earlier section covered the general influencing factors on die casting costs. This section emphasizes on cost incurred in making primarily die cast molds.
Mold Design
Mold design is a variable cost that scales with geometry complexity. A simple mold for flat, uniform parts may cost as little as $5,000, while intricate molds with slides, cores, or multi-cavity setups can exceed $100,000. The design fee for making such molds is additional, which accounts for about 2 to 3% of the total die cast mold cost.
For cost optimization, you can simplify geometry as much as it’s possible. For instance, you can eliminate unnecessary undercuts, and use standardized mold bases. This not only saves cost but also 10 to 15% time.
Cast Mold Material
Mold materials directly impact durability and cost. Common choices include:
- H13 Steel: High durability (100,000+ cycles), ideal for high-volume production. Costs $50–$80/kg.
- P20 Steel: Mid-range (50,000 cycles), costs $30–$50/kg.
- Aluminum: Lightweight and cheaper ($20–$30/kg) but limited to 5,000–10,000 cycles (low-volume prototypes).
To get the most financial benefit, the suggestion is to match die casting material with production volume and reuse mold bases for future projects.
Manufacturing Techniques
The metal mold is often prepared through machining, or if the design is more intricate, wire EDM can be used. Machining is generally a cheaper process than wire EDM. The average milling rate is $40/hour. The wire EDM is over $100//hour.
To save costs, you can either remove the unnecessary complexity from the design so that it can be made via machining. Or you can combine it with wire EDM, rough cutting/cavities may be made via machining, and wire EDM can be used for finishing the required geometry.
Die Cast Part Costs Analysis
Mold making is one component of the die casting process. Once the mold is ready, it’s used in a casting machine where molten metal is injected. This section focuses on costs beyond the mold: material, machine, and labor.
Die Casting Machine Price
Die casting machines are categorized into hot chamber (for low-melting-point metals like zinc) and cold chambers (for aluminum and magnesium). However, die casting machine costs primarily change based on the clamping force (measured in tons) and the shot volume each can handle.
Generally, the cost of these machines falls between $30,000 to $100,000. However, the important aspect to us is how much of the total cost comes into play per part. That can be calculated by dividing the total cost of the machine over its service life and the die casting parts it can make in a day.
The table below illustrates the cost per shoot in different setups:
| Clamping Force (tons) | Shot Volume (per kg) | Casting Size/Area (cm2) | Price/Shot ($) |
| 160 – 300 | 0.8 – 2.9 | 72.5 – 335 | 0.2 – 0.5 |
| 300 – 400 | 2.7 – 4.7 | 275 – 490 | 0.5 – 1 |
| 400 – 500 | 4.3 – 7.0 | 400 – 680 | 0.8 – 1.1 |
| 600 – 800 | 4.3 – 11.2 | 395 – 940 | 1.4 – 3.6 |
Casting Material Cost
Material costs vary based on the alloy type (aluminum, zinc, magnesium), the specific volume (die cast size), and how much material is wasted per casting. Generally, the material waste rate is 8 to 10%.
The table below showcases the costs of different materials, their relative die cast tooling cost, and lead times:
| Material | Unit Price (per kg) | Relative Tooling Cost | Lead Times (weeks) |
| Aluminum | $4.00 | 1.0x | 6 – 8 |
| Magnesium | $6.20 | 1.3x | 7 – 9 |
| Zinc | $3.20 | 0.8x | 5 – 8 |
| Copper | $8.00 | 1.5x | 8 – 11 |
Labour Cost
It has been observed that total labor costs (deburring -, packaging- and inspection costs) account for 1.5% of the die-casting blank cost. The trend may be different based on your locality.
How to Calculate Die Cast Part Costs: A Mathematical Perspective
Till now, we briefed you on how each factor contributes to die casting costs. Now, this section focuses on the mathematical formulas for estimated cost calculation. You can plug in the relevant values and get an estimated cost.
We’ll start with the total die casting part cost equation, and then break down each variable step-by-step.
Total Part Cost (Kt)
The total of a die casted part is represented as:
Total Part Cost = Kt = Kd/N + Ke +Km
Where Kd represents the die construction, N is the production volume, Km is the casting material cost, and Ke is the processing cost. The mathematical relation shows the higher the production volume, the lower the cost per part, and that’s what we have argued in the whole article. s
Die Construction Cost (Kd)
The die construction cost is evaluated with this equation:
Kd = (0.8Cdc + 0.2 Cdm) x Reference Mold Cost
Here, is Cdc construction cost complexity factor and Cdm is the material complexity factor. The reference cost is the base value for a simple part (between $5,000 to 50,000).
Material Cost (Km)
Material cost is primarily dependent upon the material cost per kg and the loss rate during casting, which is 8 to 10%. Here’s the relation to determine material cost.
Km = (V ×ρ× Kp)/(1 – Loss Rate)
Where V is the volume, and ρ is the density of the casting material.
Processing Cost (Ke)
The processing costs include both the cost of machining and costs of the labor involved.
Ke = (t / Y × Ch) + Labor Cost (1.5% of Km)
Here, t is the cycle time of the machine, Y is the yield rate, and Ch represents the machine’s hourly rate. Typically, lower melting point metal has quicker cycle times and costs less. For example, aluminum casting cost is less than copper.
The Online Die Cast Cost Tooling Estimator
We know it may not be a cup of tea to evaluate the costs with such complex equations for most. So, here’s an online die casting cost calculator, where you can plug in the parameters of your part (sizing and other related costs) and get an estimate of how much it could cost to make the whole part.
Costs of Die Casting vs CNC Machining
When choosing between die casting and CNC machining, cost is often a deciding factor. Generally, CNC machining is cheaper for small batches, but die casting becomes economical at scale. The question is: to what extent?
Single vs Multiple Parts
In CNC machining, you can create one-off parts without much investment in extra tooling. The cost stays roughly the same for one or multiple parts.
A permanent mold and tooling accessories are required for metal casting setup, which is a huge investment for a single part. However, if production scales to hundreds or thousands of die cast parts, the cost per unit drops, and so does the collective time to make a part.
Process Complexity
Casting with permanent die tooling involves multiple steps: designing a precise mold, melting metal, pouring it into the machine, and extracting the part. This requires significant labor and time.
Whereas CNC machining is more automated. Once instructions are fed into the machine, the CNC head operates smoothly, and parts are easily extracted.
Surface finish
Die casting offers a better surface finish than most casting techniques, but CNC machining provides a smoother finish. If you need a polished die cast surface, post-processing (e.g., machining) is required, adding cost.
Should I Invest in a Die Casting Machine?
The cost-effectiveness of the process depends on your use case and production volume. If you’re making small batches or prototypes (common for most businesses), investing in a casting machine would not be a wise choice.
However, if your parts are too large for CNC machining or you need high volumes (hundreds or thousands of units), die cast process becomes essential for efficient production.Get a Quote for Your Die Casting Projects
Get a Quote for Your Die Casting Projects
If die casting fits your needs, outsourcing to a service provider like Rapid Direct is often the best approach for businesses. We offer metal die casting services for non-ferrous metals, handling parts up to 12 kg in weight with wall thicknesses as low as 0.8 mm. For an exact quote on a custom die casting, contact our team instantly to discuss details and receive a customized solution.
Conclusion
The article’s major aim was to provide a die casting cost analysis. It is evident that die cast manufacturing is indeed a costly endeavor. The low cost die casting concept can only be realized when producing a very high volume of parts.
Throughout the article, we have thoroughly presented all factual and mathematical formulas. The tabular values are derived from limited industry data and may be considered approximations—they may or may not align with costs in your specific demographics. For an exact feasibility and cost breakdown of your project, you’ll need to contact a service provider like RapidDirect.
FAQs
Die casting isn’t that cheap. People sometimes call it economical because the process can be fast and efficient, but that’s usually because service providers have fine-tuned their setup and there are doing the process at scale. The reality is that it requires a decent initial investment in equipment and tooling, so it’s only cost-effective when you’re producing a lot of parts to spread out those costs.
Mold flow analysis definitely helps reduce costs. Before CAD technology, mold design was expensive because it involved a lot of trial and error. But with simulation analysis, you can actually see how molten metal flows through the mold before it’s made. This lets you optimize the design and process upfront, saving money in the long run.
Reusing old molds can help cut down on die cast mold costs, but only if the mold still has a solid frame. You don’t want to use one that’s too worn out. When a mold is nearing the end of its life, it’s usually better to just make a replica instead of trying to keep using the old one.
