Comprehensive Metal Casting Solutions: From Design to Mass Production

Table of Contents

One-Stop Metal Casting Services

Design for Manufacturability (DFM)

Rapid Prototyping

Core Casting Processes We Offer

Aluminum Die Casting

Zinc Die Casting

Copper-Based Alloy Casting

In-House Tool and Die Making

Post-Processing and Surface Treatments

Scalable Manufacturing: From Prototype to Production

Why Choose Neway for Your Metal Casting Needs?

Frequently Asked Questions

Metal casting is a highly established and scalable manufacturing process that produces net-shape or near-net-shape metal parts with complex geometries, superior repeatability, and excellent dimensional accuracy. At Neway, we provide comprehensive metal casting solutions that cover every production phase—from early-stage design for manufacturability to tooling, high-pressure die casting, secondary machining, and post-finishing. Our vertically integrated approach enables high-performance component delivery across automotive, aerospace, telecommunications, electronics, and industrial automation industries.

Leveraging our core services in aluminum die casting, zinc die casting, and copper die casting, we meet both prototype and volume production demands with a strong focus on consistency, mechanical strength, and surface quality.

One-Stop Metal Casting Services

Design for Manufacturability (DFM)

The foundation of a successful casting project begins with precise and application-driven design. At Neway, our design and engineering teams utilize advanced CAD/CAM platforms and casting simulation software (e.g., ProCAST, MAGMASOFT) to optimize gating, cooling, and fill patterns. DFM analysis ensures minimized warpage, internal porosity, and underfill, while enabling consistent wall thicknesses of 1.5 mm for aluminum and as low as 0.7 mm for zinc. We also provide mold flow analysis and finite element analysis (FEA) to enhance structural integrity in mission-critical components.

Rapid Prototyping

Accelerated product development is supported by our versatile rapid prototyping capabilities. Depending on material and geometry, we offer 3D printing using SLA, SLS, or DMLS for metal and plastic parts with tolerance levels reaching ±0.1 mm. Additionally, urethane casting is ideal for producing functional plastic prototypes in small volumes (10–100 units) with lead times as short as 3–5 business days.

Core Casting Processes We Offer

Aluminum Die Casting

Our aluminum die casting solutions are designed for applications requiring high strength-to-weight ratios, dimensional stability, and thermal management. Alloys such as A380 (tensile strength ~317 MPa) and A356 are widely used in automotive powertrain housings, electronic enclosures, and structural components. These materials exhibit excellent castability, low shrinkage rates (~0.6%), and good corrosion resistance. Typical casting dimensions range up to 800 mm with weight tolerances controlled to ±3%.

Zinc Die Casting

Our zinc die casting process is ideal for intricate components requiring tight tolerances (±0.03 mm), high strength (up to 380 MPa for Zamak 2), and excellent surface finish. Zinc alloys, such as Zamak 3, Zamak 5, and ZA-8, are selected for parts such as connectors, mechanical locks, and consumer goods. Their low melting point (~385°C) results in longer tool life and rapid cycle times (<30 seconds per shot).

Copper-Based Alloy Casting

Our copper die casting capabilities support high-performance alloys such as Brass 360 and CuNi10Fe1, commonly used in electrical and marine systems. Copper alloys provide excellent thermal conductivity (up to 390 W/m·K), corrosion resistance in seawater environments, and exceptional mechanical wear resistance. Complex parts up to 5 kg can be die cast with precision gating systems to reduce porosity and maintain internal grain structure.

In-House Tool and Die Making

Tooling quality is critical to achieving precision casting output. Neway’s dedicated tool and die making department fabricates and maintains multi-cavity, high-pressure molds using materials such as H13 tool steel (hardness HRC 44–52), P20 steel, and tungsten carbide. Our EDM and CNC tooling systems achieve mold tolerances of ±0.01 mm. Each mold is designed for durability up to 1 million cycles, optimized for heat dissipation, part ejection, and low maintenance downtime.

Post-Processing and Surface Treatments

Neway provides fully integrated post-processing operations to bring parts to specification and enhance their functional or aesthetic qualities:

Post Machining: We use high-precision 3-, 4-, and 5-axis CNC machines to perform reaming, threading, boring, and milling operations, achieving feature tolerances down to ±0.005 mm.
Sand Blasting and Tumbling: Improve surface uniformity to Ra 1.6–3.2 µm and remove sharp edges or flash.
Painting and Powder Coating: Available in single- or multi-layer applications, providing up to 1,000 hours of corrosion resistance in salt spray tests.
Anodizing and Arc Anodizing: Suitable for aluminum parts requiring increased surface hardness (up to 500 HV), electrical insulation, and color uniformity.

Scalable Manufacturing: From Prototype to Production

Neway supports full production scalability, from concept validation to serial production exceeding 1 million parts annually. Through our low volume manufacturing and mass production pipelines, we deliver consistent quality through automated cell production, process monitoring (SPC), and in-line inspection systems. Parts are validated with CMM, X-ray inspection, and full PPAP documentation where required. Our one-stop solutions reduce lead times, with T1 samples typically delivered in 15–25 working days depending on tooling complexity.