High-Pressure Die Casting Solutions
Ozbros provides advanced high-pressure die casting (HPDC) solutions for aluminium and zinc components, enabling the efficient production of complex parts with excellent dimensional accuracy, repeatability and surface quality.
Precision Aluminium High-Pressure Die Casting Solutions
High-pressure die casting is one of the most widely used manufacturing methods for high-volume production of precision aluminium components. Using automated casting systems and modern process control technologies, Ozbros manufactures cast parts ranging from 20 g to 20 kg, ensuring stable production performance and consistent product quality.
Our HPDC facilities utilise state-of-the-art die casting machines with fully integrated automation, allowing us to produce complex geometries with tight tolerances while maintaining high production efficiency.
Advanced Die Casting Technology
Our production lines are equipped with modern high-pressure die casting machines and automated process systems designed to ensure optimal casting conditions throughout the manufacturing cycle.
Key production features include:
- Automated metal pouring systems
- Individual holding furnaces for each casting machine
- Automated die lubrication systems
- Controlled die heating and cooling technology
- Integrated process monitoring and quality control
- In-house machining using advanced CNC technology
These technologies allow Ozbros to deliver precision aluminium die cast components with consistent material structure, reduced porosity and high dimensional stability.
Die Casting Machine Capabilities
Our production facilities include a wide range of high-pressure die casting machines designed to support both medium and large component manufacturing.
Machine capacities include:
- 2300 ton
- 1650 ton
- 1350 ton
- 1320 ton
- 1250 ton
- 1100 ton
- 900 ton
- 880 ton
- 720 ton
- 580 ton
- 550 ton
- 500 ton
- 400 ton
- 320 ton
- 160 ton
Aluminium High-Pressure Die Casting Alloys
Aluminium alloys are widely used in high-pressure die casting because of their excellent strength-to-weight ratio, corrosion resistance and thermal conductivity. These materials are particularly suitable for structural and mechanical applications where lightweight components are essential.
AlSi9Cu3 – EN AC 46000
One of the most widely used aluminium die casting alloys. It provides good strength, wear resistance and excellent castability.
Typical applications include:
- Automotive engine components
- Gear housings
- Structural brackets
- Pump housings
- Mechanical enclosures
Industries using this alloy:
- Automotive manufacturing
- Industrial machinery
- Mechanical engineering
AlSi12(Fe) – EN AC 44300
This aluminium-silicon alloy provides excellent fluidity and casting performance, making it ideal for complex geometries and thin-wall components.
Typical applications include:
- Electronic housings
- Lighting components
- Small mechanical parts
- Complex aluminium cast structures
Industries using this alloy:
- Electronics manufacturing
- Automotive systems
- Lighting equipment
AlSi12Cu – EN AC 47100
This alloy offers improved strength and mechanical performance, particularly in components subjected to higher loads.
Typical applications include:
- Engine covers
- Mechanical housings
- Pump components
- Structural castings
Industries using this alloy:
- Automotive powertrain systems
- Heavy machinery
Industrial equipment manufacturing
AlSi10Mg – EN AC 43000 series
Known for excellent strength, corrosion resistance and weldability, making it suitable for precision engineering components.
Typical applications include:
- Structural aluminium components
- Pressure housings
- High-strength mechanical parts
Industries using this alloy:
- Automotive
- Aerospace components
- Mechanical engineering
Zinc Die Casting Alloys (Zamak)
Zamak alloys are zinc-based die casting materials widely used in high-precision manufacturing where excellent surface finish and dimensional accuracy are required.
Compared with aluminium, zinc alloys allow:
- Thinner wall sections
- Superior surface finish
- High dimensional accuracy
- Excellent plating and coating compatibility
These properties make Zamak ideal for precision mechanical parts, decorative hardware and complex small components.
Zamak Alloy Types
Zamak 2
Zamak 2 provides very high strength and hardness, making it suitable for demanding mechanical components.
Typical applications:
- Gears and mechanical components
- Industrial hardware
- High-strength brackets
Industries using Zamak 2:
- Industrial equipment manufacturing
- Mechanical engineering
Zamak 3
Zamak 3 is the most widely used zinc die casting alloy due to its excellent balance of strength, ductility and casting stability.
Typical applications include:
- Automotive interior components
- Electronic housings
- Connectors and fittings
- Mechanical parts
Industries using Zamak 3:
- Automotive
- Electronics
- Consumer products
Zamak 5
Zamak 5 offers higher strength and improved creep resistance compared with Zamak 3.
Typical applications include:
- Automotive hardware
- Door handles and locks
- Mechanical assemblies
- Furniture fittings
Industries using Zamak 5:
- Automotive interior hardware
- Architectural hardware
- Furniture manufacturing
Zamak 7
Zamak 7 provides excellent fluidity and surface finish, making it suitable for complex shapes and decorative components.
Typical applications include:
- Decorative hardware
- Precision housings
- Electrical components
Industries using Zamak 7:
- Electronics manufacturing
- Decorative metal products
- Consumer goods
Prototyping & Tool Development
To support product development and early-stage production, Ozbros offers advanced prototyping capabilities using soft tooling and production tooling solutions.
Typical High-Pressure Die Casting Applications
Our HPDC production supports the manufacture of complex aluminium components such as:
- Engine brackets
- Support brackets
- Filter housings
- Filter heads
- Oil suction pipes
- Heating system components
- Flanges
- Gear-type fuel pumps
- Mechanical fuel and oil pumps
- Electric fuel pumps
- Chain case covers
These components are typically used in automotive, industrial equipment, mechanical systems and engineering applications.
Testing & Quality Control
Ozbros operates a comprehensive test and validation centre to ensure that all high-pressure die cast components meet strict technical and quality requirements.
Testing and inspection capabilities include:
- Industrial X-ray inspection
- Spectrometer chemical analysis
- Metallurgical microscopy
- Density and density index measurement
- Metallurgical sample preparation equipment
- Penetrant testing
- 3D measurement systems
- Optical inspection equipment
- Surface roughness measurement
- Industrial endoscope inspection
- Cleanliness testing laboratory
- Spring force testing
- Static and dynamic torque measurement
- Precision measurement instruments
- Profile projector systems
These advanced inspection technologies ensure that every component meets the required material quality, dimensional accuracy and structural integrity standards.
Value-Added Manufacturing
Beyond die casting operations, Ozbros offers a complete range of value-added manufacturing services, enabling the delivery of finished components ready for integration into customer systems.
These services include:
- CNC machining
- Robotic and manual welding
- Shot blasting
- Coating operations
- Laser marking
- Ultrasonic cleaning
- In-house tooling design and manufacturing
This integrated manufacturing approach enables Ozbros to provide complete aluminium component solutions from casting to finished product.
