In-House Aluminum Die Casting Molds Development Services

Provide Die Casting Dies Design and Manufacturing Services Since 1995

CEX Casting - Your Trusted Die Casting Molds Manufacturer

Die casting molds are the foundation of aluminum die casting manufacturing. At CEX Casting, we design and manufacture durable, high-efficiency molds that ensure consistency and strength in every part we produce. With over 29 years of experience, our team integrates flow simulation, precision CNC machining, and heat control to build tools that meet complex design and performance demands. CEX Casting is your trusted partner for reliable, high-quality die casting dies built for demanding industries.

High-Precision Mold Machining Equipment for Your Die Casting Dies

Precision Mold CNC Machining

Large Mold CNC Machining

EDM for Die Casting Mold

Aluminum Die Casting Parts Supproted by Our Precision Die Casting Molds

Die Cast Handle

Die Cast Fan Cover

Die Cast Motor Drive Enclosure

Die Cast LED Light Housing

Our Typical Die Casting Molds Cases

Die Casting Mold for Electrical Parts

Die Casting Mold for Automotive Parts

Die Casting Mold for Machinery Parts

Mold Simulation & Precision Validation

At CEX Casting, our engineers utilize mold flow simulation software such as ProCAST to optimize gating, cooling, and parting line structures before tooling commences. This data-driven approach minimizes trial-and-error, shortens development cycles, and guarantees stable, defect-free die casting results.

Experienced Mold Engineering Team

CEX Casting’s engineers use simulation results to guide mold design, ensuring smooth flow, proper cooling, and tool durability. Our in-house team supports clients by reviewing geometry, refining casting parameters, and delivering mold solutions aligned with production needs.

Die Casting Molds Materials

Different aluminum die casting die materials come with pros and cons, and various factors need to be comprehensively considered when selecting them.

High-Hardness Steel is suitable for manufacturing products that require high precision, high surface quality, and high wear resistance; however, it comes with a higher mold budget and is prone to cracking.

Heat-Treated Steel has a long service life and excellent wear resistance, but has poor thermal conductivity and requires heat treatment.

Aluminum Alloy is lightweight, sturdy, and long service life, but the hardness and strength are not as good as the other two options.

When selecting, it is necessary to comprehensively consider production needs in order to choose the most suitable aluminum die casting mold material.

How Much the Die Casting Dies Cost?

The price of die casting dies typically ranges from $900 to $15,000. CEX selects suitable mold materials based on product structure and customer requirements, designs the mold structure, determines the number of cavities, and plans the gate runner system.

For products with lower technical demands, we use more economical materials and fewer cavities to reduce costs. For higher-precision requirements, we opt for premium materials and more cavities to optimize per-unit processing costs.

To provide an accurate quote, we carefully evaluate your drawings and specifications. We aim to deliver a quotation within 10-15 hours (excluding holidays) after receiving all necessary details.

In-house Mold Manufacturing

CEX Casting runs a fully equipped tooling workshop to ensure every die meets exact standards. Our team uses high-speed CNCs, EDM, and strict quality control to deliver durable, high-precision molds. This in-house capacity shortens lead time, ensures consistency, and supports stable die casting production.

Die Casting Die Lifespan

The service life of die casting dies typically ranges from 80,000 to 100,000 cycles, influenced by material quality, heat treatment, product structure, and wall thickness. Thicker-walled aluminum die castings generally result in shorter mold lifespans.

With CEX, you only need to pay the initial development cost. We handle all subsequent maintenance, remodeling, and even additional mold development if needed for high-volume production. This ensures uninterrupted manufacturing without additional financial burden on your side.

Unique Mold Design for High Strength Squeeze Castings

Our molds feature an optimized feeding system and precision exhaust structure to ensure uniform metal flow while eliminating gas entrapment. For complex part geometries, integrated sand cores and specialized gate designs maintain cavity-filling control, enabling consistent solidification even for thick-walled sections.

The mold construction prioritizes durability and precision, with optimized cooling channels that promote directional solidification for fine grain structure. This design approach allows the mold to withstand high-pressure cycles while consistently producing dimensionally accurate castings without porosity.

By combining these innovative mold technologies, we achieve tight tolerances and high-density surfaces in the final castings. The design also accommodates T6 heat-treatable alloys, ensuring the mold meets both structural and material requirements for high-performance applications.

Advanced Mold Manufacturing and Quality Inspection Equipment

No.	Name	Stroke	QTY
1	5-axis CNC Machining Center	Ø850 × 600MM	3
2	High-Speed Milling Machine	1000 × 800 × 500MM	2
3	3-axis CNC Machining Center	2000 × 1500MM	2
4	4-axis Vertical Machining Center	Ø300 × 800MM	6
5	CNC Lathe	Ø300 × 1000MM	4
6	Wire Cut EDM Machine	400 × 400 × 200MM	3
7	EDM Die-Sinking Machine	500 × 400 × 400MM	2
8	Surface Grinding Machine	600 × 300 × 200MM	2

No.	Name	Specification	QTY
1	Coordinate Measuring Machine (CMM)	800×1200×600 mm, MPE: 3.0 μm	1
2	Video Measuring System (VMS)	Measuring range: 250×150×150 mm, Accuracy: ±2.5 μm	1
3	Spectrometer	Wavelength range: 120–780 nm, Accuracy: ≤0.3%	1
4	Tensile Strength Tester	Max load: 50 kN	1
5	Hardness Tester	Brinell / Rockwell / Vickers compatible	1
6	X-Ray Machine	Tube voltage: 160 kV, Resolution: ≤2 μm, Penetration: up to 20 mm Al	1
7	Helium Leakage Testing Equipment	Helium sensitivity: 1×10⁻⁶ Pa·m³/s, Pressure range: 0–0.6 MPa	1
8	Granite Measurement Bench	1200×1000 mm / 1000×750 mm	2
9	Digital Height Gauge	Measuring range: 0–600 mm	2
10	Vernier Caliper Set	0–100–150–200–300–600–1000 mm full range	7
11	External/Internal Micrometers	External: 0–150 mm / Internal: 12–100 mm	5
12	Pin Gauge / Gauge Blocks	0.5–12 mm / 1.0–100 mm, with 0.01 mm spacing	20

Comprehensive FAQ for Die Casting Molds

CEX Casting specializes in die casting mold design and in-house manufacturing. With three dedicated working bases and over 50 experienced staff, we manage the entire tooling process, from simulation and design to machining and assembly. Backed by over 29 years of expertise, our in-house mold production ensures high precision, fast turnaround, and consistent quality for every project.

What Is an Aluminum Die Casting Mold?

An aluminum die casting mold is a precision-made steel tool used to form molten aluminum into specific shapes under high pressure. It typically consists of two halves, one fixed and one movable, that form the cavity of the desired part.

How Does the Die Casting Process Work With the Mold?

The process begins when the two halves of the mold close tightly to form a sealed cavity. Molten aluminum is then injected into the cavity at high pressure to ensure it fills every detail quickly and evenly.

As the aluminum fills the mold, built-in cooling channels help it solidify within seconds. Once the metal has hardened, the mold opens, and ejector pins push the finished part out. The mold then closes again, ready for the next cycle.

How Much Does It Cost to Make a Die Casting Mold?

The cost of making a die casting mold typically ranges from a few thousand to over ten thousand U.S. dollars, depending on several factors. These include the part size, design complexity, number of cavities, tolerance requirements, and the type of steel used for the mold.

Simple Molds (Several Thousand USD)

Features: Single cavity, simple geometry, small-sized parts
Typical Use: Low-complexity parts, prototyping, or small production runs
Estimated Cost: $3,000–$8,000
These molds are quicker to produce and lower in cost, suitable for basic shapes and low-volume needs.

Medium-Complexity Molds (Several Thousand to Over Ten Thousand USD)

Features: Multi-cavity or moderately complex structures, mid-sized parts
Typical Use: Medium-volume production, parts with moderate precision or surface finish requirements
Estimated Cost: $8,000–$20,000
These molds may include insert cores, enhanced cooling systems, and more refined tolerances for ongoing production.

High-Complexity Molds (Over Ten Thousand USD)

Features: Large part size, intricate geometry, multiple sliders or lifters, tight tolerances
Typical Use: Automotive structural parts, industrial components, long-term mass production
Estimated Cost: $20,000–$100,000+
These molds require advanced design, simulation, precision machining, and extended lead times. They’re built for durability and repeatability over many thousands of cycles.

How Long Does It Take to Build a Die Casting Mold?

The time required to build a die casting mold typically ranges from several weeks to a few months, depending on the complexity of the part, the number of cavities, and the level of precision required.

Simple Molds (Short Lead Time)

Features: Basic geometry, single cavity, minimal moving parts
Estimated Time: 3 to 5 weeks
These molds are straightforward to design and manufacture, making them suitable for prototypes or simple production parts.

Medium-Complexity Molds (Standard Projects)

Features: Multi-cavity designs, moderate part complexity, standard tolerances
Estimated Time: 6 to 10 weeks
These molds require more design effort, precise machining, and functional features such as basic sliders or inserts.

High-Complexity Molds (Advanced Projects)

Features: Large size, intricate geometry, multiple sliders, lifters, or interchangeable inserts
Estimated Time: 10 to 16+ weeks
These molds involve extensive design validation, mold flow simulation, precision tooling, and longer trial and adjustment periods.

How Do You Determine the Number of Cavities Needed in a Mold?

The number of cavities in a die casting mold is determined by factors such as production volume, part size, cycle time goals, and machine capability. Here’s how it varies by situation:

Low-Volume or Prototyping

Typical Cavity Count: 1 cavity (single-cavity mold)
Reason: Keeps tooling cost low and allows for quicker delivery, ideal for trial runs or small orders (e.g., under 5,000 parts/year).

Medium-Volume Production

Typical Cavity Count: 2–4 cavities
Reason: Balances cost and output for annual volumes ranging from 10,000 to 50,000 parts. Fits well with mid-sized machines and standard cycle times.

High-Volume Production

Typical Cavity Count: 4–8 or more cavities
Reason: For mass production of 100,000+ parts annually, increasing cavity count reduces cost per part and boosts productivity. Machine size and shot weight must support the total volume per cycle.

What Type of Steel Is Used to Make Aluminum Die Casting Molds?

Aluminum die casting molds are typically made from high-performance tool steels that can withstand repeated thermal and mechanical stress. The most commonly used grades include:

H13 Steel

Widely used for aluminum die casting, H13 offers excellent thermal fatigue resistance, high hardness, and good toughness. It performs well under continuous heating and cooling cycles, making it ideal for high-volume production.

SKD61

This is the Japanese equivalent of H13 and offers similar properties. It’s commonly used in Asian markets and ensures durability, crack resistance, and stable mold performance over many cycles.

Other Alloy Tool Steels

In specific cases, mold makers may use specialty steels or enhanced versions of H13 with added elements for improved heat resistance or wear performance, especially for molds with complex features or long service life requirements.

How Many Shots Can a Typical Aluminum Mold Produce?

A typical aluminum die casting mold can produce anywhere from tens of thousands to several hundred thousand shots, depending on the mold design, steel quality, maintenance, and casting conditions.

Basic molds using standard H13 or SKD61 steel can often last 50,000 to 100,000 shots.
Well-maintained molds with optimized cooling and proper heat treatment can reach 200,000 shots or more.
High-end molds used in precision or automotive applications may exceed 300,000 shots, especially when regularly serviced and rebuilt as needed.

What’s the Difference Between a Die Casting Mold and an Injection Mold?

Die casting molds and injection molds are both precision-engineered tools used in high-volume manufacturing, but they differ significantly in materials processed, working environments, design considerations, and tooling requirements.

Processed Materials

Die Casting Molds are used to form molten metals, such as aluminum, zinc, or magnesium, by injecting them into the mold at high pressure.

Injection Molds are used for plastics, such as ABS, nylon, polypropylene, or polycarbonate, which are melted and injected at much lower temperatures.

Temperature and Pressure Requirements

Die casting involves extreme temperatures (typically 600–700°C for aluminum) and injection pressures that can exceed 1000 bar.

Injection molding operates at lower temperatures (typically 200–300°C) and lower pressures, which puts less thermal and mechanical stress on the mold.

Mold Material and Durability

Die casting molds must be made from high-temperature-resistant tool steels, like H13 or SKD61, to endure repeated thermal cycling and abrasive molten metal.

Injection molds can be made from a wider range of steels or even aluminum for low-volume runs, as they don’t face the same level of thermal shock or erosion.

Cooling and Ejection Systems

Die casting molds require aggressive cooling and strong ejection systems due to the fast solidification of metals and higher shrinkage force.

Injection molds use more moderate cooling designs, and plastic parts are generally easier to eject due to lower rigidity and adhesion.

Precision and Tolerance

Both molds can produce high-precision parts, but die casting must account for metal shrinkage, air entrapment, and thermal contraction, making mold design more challenging.

Injection molds often allow finer detailing in surface texture and are more forgiving in terms of draft angles and undercuts.

Can One Mold Be Used for Different Aluminum Alloys or Part Revisions?

In some cases, a single die casting mold can be used for different aluminum alloys, but it depends on the specific properties of each alloy. Alloys with similar melting temperatures and flow characteristics, such as A380 and ADC10, may be interchangeable with minor process adjustments. However, if the alloy differs significantly in shrinkage rate, thermal conductivity, or chemical reactivity, the mold may require surface treatment or redesign to ensure proper performance and part quality.

For part revisions, small design changes like logo updates or minor dimensional tweaks can sometimes be accommodated by modifying the mold inserts. However, major design changes, such as altering wall thickness, adding ribs, or changing overall dimensions, usually require a new mold or significant tooling modifications.

Do You Offer Mold Design and Mold Flow Simulation Before Production?

Yes, at CEX Casting, we provide full mold design and mold flow simulation services before production begins. Our engineering team uses advanced software such as ProCAST to simulate metal flow, solidification, and potential defect areas such as air entrapment or cold shuts.

This pre-production analysis allows us to optimize the gating system, cooling layout, and parting lines, reducing trial-and-error during tooling and improving mold performance. By identifying and resolving issues early, we ensure faster mold validation, fewer casting defects, and higher production efficiency for your project.

Do You Test the Mold Before It Goes Into Mass Production?

Yes, at CEX Casting, we conduct comprehensive mold testing before mass production. Each mold undergoes a trial run to verify dimensional accuracy, part filling, ejection function, and cooling performance.

We evaluate the sample castings using tools like CMM, X-ray inspection, and visual checks to ensure the mold produces defect-free parts. If any issues are found, we fine-tune the mold before final approval. This process ensures stable performance, high precision, and reliable quality when the mold enters full-scale production.

What Tolerances Can Be Achieved With Your Die Casting Molds?

At CEX Casting, our die casting molds are designed to achieve tight dimensional tolerances that meet or exceed international standards. For typical aluminum die casting parts, we can maintain:

±0.05 mm to ±0.10 mm for general dimensions
±0.02 mm or better for critical features (with post-machining if needed)
DIN ISO 8062-3 (DCTG 5–6 / GCTG 3–5) standard compliance for most parts

The achievable tolerance depends on the part’s geometry, wall thickness, and alloy type. We also use CMM inspection and mold flow simulation during development to ensure consistent, repeatable precision throughout the production cycle.

How Do You Inspect Mold Quality During and After Manufacturing?

At CEX Casting, we follow a strict quality control process to ensure every mold meets performance and durability standards.

During Manufacturing

We perform in-process inspections at key stages such as CNC machining, EDM, and assembly. Each critical dimension is checked against the 3D mold design using precision tools like CMMs and height gauges. Hardness testing and steel certification are also conducted to verify material quality.

After Mold Completion

Once the mold is assembled, we conduct a trial casting to evaluate filling, ejection, and part accuracy. Sample castings are inspected using X-ray analysis, CMM, and visual checks to detect any defects. If needed, we adjust the mold to ensure optimal performance before mass production begins.

Do You Offer Maintenance or Storage Services for Molds After Production?

Yes, at CEX Casting, we provide both mold maintenance and storage services to support long-term, stable production for our clients.

Mold Maintenance

We offer free regular maintenance for all customer molds, including cleaning, inspection, polishing, and anti-rust protection. If a mold reaches the end of its service life, we will build a new mold free of charge; you only need to pay for the initial mold.

Mold Storage

All molds are stored on dedicated mold racks at our facility to keep them safe, organized, and free from damage. Each mold is clearly labeled and recorded in our system. This allows us to retrieve and prepare molds quickly when repeat orders are placed.