Custom Aluminum Die Casting Manufacturer for OEM Parts
CharMax Precision provides high-quality aluminum die casting, CNC machining after casting, surface finishing and assembly solutions for industrial OEM customers.
Engineering response within 24 hours on business days. Quotation within 24-48 hours of receiving 2D/3D files.
Max clamping force
1,250 t
Machined tolerance
±0.02 mm
Max part weight
12 kg
Parts per year
4 M+
ISO 9001:2015Certified quality system
12+ yearsAluminum manufacturing
Casting + CNCBoth in-house, one supplier
CMM inspectionDimensional reports per lot
OEM programsAutomotive to medical
Who we are
An aluminum die casting manufacturer, not a trading company
Company summary
CharMax Precision is an ISO 9001 certified aluminum die casting manufacturer in Dongguan, Guangdong, China, producing custom high pressure die cast aluminum components in A380, ADC12, A360 and aluminum-silicon alloys for automotive, robotics, industrial equipment, consumer electronics and medical device OEMs.
We manufacture in our own facility in Dongguan, Guangdong, China. Casting, CNC machining after casting, surface finishing, assembly and inspection all happen under one roof, which means one company is accountable for your entire tolerance stack and there is no freight or finger-pointing between operations.
Typical programs run from 500 to 500,000+ parts per year, in part weights from 20 g to 12 kg per casting, for OEM customers in automotive, robotics, industrial equipment, consumer electronics and medical devices.
Figures below are our standard production envelope.
Primary process
High pressure aluminum die casting (cold chamber)
Alloys
A380, ADC12, A360, A413 and aluminum-silicon grades
Machine tonnage
160 to 1,250 tons of cold chamber clamping force
Part weight range
20 g to 12 kg per casting
Wall thickness
1.5 mm typical, 1.0 mm achievable on small parts
Tolerances
±0.1 mm on as-cast features, ±0.02 mm on machined features
Production volume
500 to 500,000+ parts per year
Tooling lead time
25 to 40 days for production tooling
Production lead time
15 to 25 days after tooling approval
Certification
ISO 9001:2015
Location
Dongguan, Guangdong, China — shipping worldwide
Manufacturing capabilities
Everything from mold design to finished, inspected parts
Six integrated capabilities cover the full route from a CAD file to packaged production
parts. You can use them as a complete package or engage us for casting alone.
Why engineers choose die cast aluminum for production parts
Die casting is the most efficient way to produce complex aluminum parts in volume. These
are the six reasons customers move a design from machining or fabrication to casting.
2.7 g/cm³
Lightweight
Aluminum weighs about one third of steel and roughly 40% less than zinc. For anything that moves, mounts overhead or ships in volume, that weight reduction goes straight to energy consumption, payload and freight cost.
324 MPa
High strength-to-weight ratio
A380 reaches 324 MPa ultimate tensile strength as cast. Combined with low density, aluminum castings deliver structural stiffness competitive with much heavier steel or iron parts, which is why automotive and robotics designers convert to aluminum first.
1.5 mm walls
Complex geometry in one shot
High pressure filling reproduces thin walls, integrated ribs, bosses, cooling fins and mounting features in a single operation. Assemblies that once needed several machined pieces and fasteners can be consolidated into one casting.
30-90 s cycles
Excellent production efficiency
Cycle times of 30 to 90 seconds and tool life of 80,000 to 150,000 shots make die casting one of the most productive metal-forming processes available. Once the die is proven, output is highly repeatable with minimal per-part labour.
Break-even ~1,000 pcs
Cost-effective at volume
Tooling is a fixed upfront cost, so the more parts you run the lower the total cost per part. Compared with CNC machining the same geometry from billet, die casting typically saves 50 to 80% per part at volumes above 5,000 pieces per year.
96-121 W/m·K
Good thermal and EMI performance
Aluminum's thermal conductivity makes it a natural choice for heat sinks and power electronics housings, and as a conductive metal it provides inherent EMI shielding that plastic enclosures need added coatings or foils to match.
Materials
Aluminum die casting alloys we run in production
Alloy choice drives strength, corrosion resistance, thermal performance, machinability and
cost. If you are unsure which grade fits your application, send the drawing and we will
recommend one with the reasoning.
OEM die casting programs across five core industries
Each industry brings different priorities: automotive wants documentation, electronics
wants cosmetic consistency, medical wants traceability. We build the program around yours.
Nine stages from engineering review to packed parts, condensed here from the full ten-stage
process. Each stage has a defined output and a defined owner, so you always know where your
program stands.
01
DFM Engineering Review
Our tooling engineers run a design for manufacturability review and return a written report. We identify wall thickness variation, draft angles, undercuts, parting line placement, ejector locations and features that would be cheaper to machine than to cast.
DFM report within 2-3 business days
02
Tooling Design
Once DFM is approved we design the die: cavity layout, runner and gate system, overflow and vent placement, cooling lines, slides and ejector system. Mold flow simulation predicts fill pattern, air entrapment and solidification before any steel is cut.
5-8 days for die design and simulation
03
Mold Manufacturing
Dies are cut from H13 hardened tool steel, heat treated to 46-50 HRC, then finished by CNC milling, EDM and grinding. Slides, inserts and ejector systems are fitted and the die is trial fitted before first shot.
25-40 days for production tooling
04
Aluminum Die Casting
Aluminum is melted and held at 660-700 °C, dosed into the shot sleeve and injected into the die at 40-100 MPa. Cold chamber machines from 160 to 1,250 tons run the part while shot profile, die temperature and cycle time are logged for every batch.
T1 samples in 5-7 days after tooling
05
Trimming and Deflashing
Runners, overflows and flash are removed by trim press, then parts are deburred and shot blasted to a uniform as-cast surface. Gate witness marks are dressed to your drawing requirements.
In-line with casting
06
CNC Machining
Castings are located in dedicated fixtures and machined on 3, 4 and 5-axis centres to bring sealing faces, bores, threads and datum features to ±0.02 mm. Machining in-house means no inter-factory shipping and one company owning the tolerance stack.
Runs parallel to casting batches
07
Surface Finishing
Parts move to the finish specified on your drawing: shot blast, powder coat, wet paint, polishing, chromate conversion or anodizing. Cosmetic parts are inspected against an agreed boundary sample under controlled lighting.
3-6 days depending on finish
08
Inspection
First article inspection covers every dimension on the drawing. Production lots are checked to an agreed sampling plan using CMM, height gauges, thread gauges, roughness testers and leak test rigs, with results issued as a dimensional report.
FAI before every production release
09
Packaging and Shipping
Parts are packed to protect machined and cosmetic surfaces, labelled to your part numbering, and shipped by sea, air or courier with full documentation. We can ship to your plant, your contract assembler or a third-party warehouse.
Inspection and documentation your quality team can audit
An ISO 9001:2015 quality system, CMM measurement, material traceability and first article
inspection on every program, with the reports to prove it.
ISO 9001:2015 quality system
Documented procedures for incoming material, process control, in-process inspection, non-conformance handling and corrective action, audited annually by an accredited certification body.
CMM inspection
Coordinate measuring machines verify dimensions, position, flatness and perpendicularity against your drawing, with printed dimensional reports issued per lot.
Material traceability
Every casting lot is traceable to its aluminum ingot batch and supplier certificate. Spectrometer analysis confirms alloy chemistry before casting begins.
Dimensional inspection
Calipers, micrometers, height gauges, bore gauges, thread gauges and custom go/no-go fixtures cover routine production checks against an agreed sampling plan.
First article inspection
A full FAI report covering every dimension on the drawing is produced and approved before any production release, and again after any tooling change.
Quality reports and documentation
Dimensional reports, material certificates, RoHS declarations, surface finish records and PPAP-format documentation packages supplied with shipments on request.
What makes us different from a generic casting supplier
01
Aluminum is all we do
We are not a general foundry that also runs aluminum. Every die, every process parameter and every finishing line in our facility is set up for aluminum alloys, which is why we can advise on alloy selection and wall thickness with confidence rather than guesswork.
02
Casting and machining under one roof
Most die casters ship castings to a separate machine shop, which adds freight, delay and a second company to blame when a tolerance is missed. We cast, machine, finish and inspect in the same facility, so one company owns your entire tolerance stack.
03
Engineers answer your emails
Your enquiry goes to a manufacturing engineer who reads your drawing, not to a sales agent who forwards it. You get a written DFM report identifying what will cost you money before tooling is cut, not after first samples fail.
04
Quality system built for OEM audits
ISO 9001:2015 certified with CMM inspection, material traceability by lot, first article inspection on every program and documented process control. We supply the dimensional reports, material certificates and PPAP documentation your quality department needs.
05
Built for long-run OEM programs
We are structured for programs that run for years, not one-off orders. Tooling is stored and maintained at our facility, spare cores can be held for critical parts, and repeat orders ship in 15 to 20 days on existing dies.
06
One partner across two processes
Through our sister CNC machining operation we support the full aluminum lifecycle: machined prototypes to validate a design, die casting once volume justifies tooling, and machining after casting on the same parts. Your design does not need to change suppliers as it scales.
Case studies
Real OEM die casting programs
Part geometry, alloy, tolerances, the problem the customer brought us and the measured
result. Names withheld where customers require confidentiality.
Die casting pays for itself above roughly 1,000 parts per year. Below that, or while you are still validating a design, CNC machining from billet is usually the faster and cheaper route. CharMax Precision runs a dedicated aluminum CNC machining operation for exactly that work, so you can prototype machined, then move to casting when volume justifies tooling.
The questions engineers and buyers ask us most often before starting a program.
What is aluminum die casting?
Aluminum die casting is a manufacturing process in which molten aluminum is injected into a hardened steel mold under high pressure, typically 40 to 100 MPa, and solidifies in seconds to form a near-net-shape part. Because the steel die is reused for tens of thousands of cycles, die casting produces complex geometry with thin walls, tight repeatability and low piece cost at production volume. It is the most efficient way to manufacture aluminum parts in quantities above roughly 1,000 pieces per year.
What aluminum alloys do you support?
We die cast A380, ADC12, A360 and A413 aluminum, along with the wider aluminum-silicon family including EN AC-46000 and AlSi9Cu3. A380 is our most widely used alloy because it balances strength, castability and machinability at the lowest cost. ADC12 is preferred for thin walls, and A360 is specified where corrosion resistance, pressure tightness or thermal conductivity matter more than price.
What production volume is suitable for die casting?
Die casting becomes economical from roughly 1,000 parts per year and remains the best process up to millions of parts per year. Because tooling is a fixed upfront investment of typically 3,000 to 25,000 USD, the tooling cost per part falls as volume rises. Below about 500 pieces, CNC machining from billet is usually cheaper. Between 500 and 2,000 pieces we can often use rapid or simplified tooling to bring the break-even point down.
Can you machine aluminum die casting parts?
Yes. CNC machining after casting is performed in-house on 3, 4 and 5-axis machining centres, using fixtures built specifically for each casting. We machine sealing faces, bearing bores, threaded holes and datum features to ±0.02 mm while the as-cast geometry stays at ±0.1 mm. Keeping casting and machining under one roof means a single company owns the whole tolerance stack, and there is no inter-factory shipping between operations.
What surface finishes are available?
Standard options are shot blasting, vibratory deburring, powder coating to any RAL or Pantone colour, wet painting, mechanical polishing, chromate conversion coating and anodizing. Powder coating is the most common choice for industrial housings because it covers minor as-cast surface variation and provides good corrosion protection. Anodizing on die cast aluminum produces a darker, less uniform finish than on wrought alloys due to the high silicon content, so we advise on it case by case.
What tolerances can aluminum die casting achieve?
As-cast features hold ±0.1 mm for the first 25 mm of dimension, with roughly ±0.02 mm added per additional 25 mm across the parting line. Linear tolerances within a single die half are tighter than dimensions spanning the parting line or a slide. Flatness is typically 0.1 mm per 100 mm, and as-cast surface roughness is Ra 1.6 to 3.2 µm. Any feature requiring better than ±0.05 mm should be machined after casting.
Request for quote
Get a quote on your aluminum die casting part
Send your 2D drawing and 3D model and a manufacturing engineer will review the geometry, confirm the alloy and return pricing with a DFM report. No obligation, no sales scripts.
Engineering response within 24 hours on business days
Quotation within 24-48 hours of receiving 2D/3D files
