Custom Parts Cost-Effective Mass Production in Metal Die Casting
In today’s competitive manufacturing environment, companies require scalable production solutions that balance speed, precision, and affordability. At Neway, we specialize in delivering high-quality custom metal die cast parts at scale. Our production systems are optimized for high-volume output, ensuring that each part meets exact specifications while minimizing per-unit costs. With full in-house capabilities spanning tooling, casting, machining, and post-processing, we provide a single-source solution for the mass production of aluminum, zinc, and copper alloy components.
Whether your needs involve millions of parts annually or steady production for multiple SKUs, our integrated metal casting services ensure repeatability, reliability, and rapid fulfillment—all backed by engineering excellence and ISO 9001:2015-certified quality systems.
Why Die Casting Is the Preferred Method for Mass Production
Die casting is one of the most cost-effective and scalable methods for producing high-precision metal parts. It involves injecting molten metal into hardened steel molds (dies) under high pressure, resulting in dense, complex components with excellent surface finishes and minimal material waste.
For mass production, die casting offers distinct advantages:
Consistent dimensional accuracy and surface quality
Rapid cycle times (as fast as 15 seconds per shot)
Tight tolerances without the need for secondary machining
Integration of complex features and tight geometries
High tooling durability for long production runs (500,000+ cycles)
Competitive per-part pricing due to economies of scale
These benefits make die casting a preferred method in automotive, aerospace, electronics, and industrial sectors—especially where lightweight, high-strength parts are needed in large volumes.
Materials for High-Volume Custom Die Casting
Neway offers a diverse portfolio of casting materials engineered for different performance criteria and mass production requirements.
Aluminum Alloys
Aluminum is widely used for its strength-to-weight ratio, corrosion resistance, and thermal conductivity. Commonly used alloys include:
A380: Industry standard for housings and structural parts. Tensile strength ~317 MPa.
A360: Improved ductility and pressure tightness, ideal for thin-walled castings.
AlSi12: Excellent fluidity and wear resistance for intricate shapes.
Applications include automotive powertrain components, heat sinks, covers, brackets, and enclosures.
Zinc Alloys
Zinc alloys offer superior precision and surface finish for high-volume parts with tight tolerances. Benefits include low melting point (~385°C), short cycle times, and long tool life.
Zamak 3: General-purpose alloy with excellent dimensional stability.
Zamak 5: Improved strength and hardness for mechanical applications.
ZA-8: Higher aluminum content for enhanced performance in dynamic loads.
Ideal for locks, gears, connectors, appliance parts, and decorative hardware.
Copper-Based Alloys
Copper and brass castings are used where conductivity, corrosion resistance, and strength are critical.
Brass 360: High machinability, used in electrical connectors and plumbing fixtures.
CuZn40: High strength and corrosion resistance for marine and industrial use.
CuNi10Fe1: Excellent resistance to seawater, used in naval and offshore systems.
These alloys are selected for specialized applications and support volumes ranging from thousands to millions of parts annually.
High-Precision Tooling for Mass Production
Tooling is the foundation of efficient, high-volume die casting. At Neway, we manufacture our own production dies using durable tool steels like H13 and P20, which are rated for hundreds of thousands of cycles with minimal maintenance.
Key capabilities include:
Mold cavity precision to ±0.01 mm using high-speed CNC and EDM
Custom mold base and insert systems for part families or rapid iteration
Thermal regulation channels to optimize mold cooling and cycle time
In-house simulation for mold filling, shrinkage, and venting
Once validated, these tools allow us to run large production volumes with excellent shot-to-shot consistency and low rejection rates.
Full-Scale Casting with Process Automation
Our mass production systems integrate automated die casting cells with real-time process control. Benefits include:
Closed-loop pressure and temperature monitoring for every cycle
Robotic part extraction, trimming, and visual inspection
Shot-to-shot traceability with barcode or RFID tracking
Inline quality control using SPC and optical measurement systems
This approach supports large-scale output with minimal operator intervention, reducing labor costs and ensuring repeatability.
Integrated Post-Processing and Final Assembly
To provide ready-to-use components directly from our facility, we offer a full suite of post-processing operations:
Post Machining: CNC operations including milling, drilling, and tapping with tolerances down to ±0.005 mm
Surface Treatments: Including anodizing, powder coating, painting, and arc anodizing
Cleaning and Finishing: Options like tumbling, sand blasting, and ultrasonic cleaning
Assembly: Manual and semi-automated component integration and final inspection
Our one-stop model helps clients reduce supply chain complexity and launch their products faster.
Industry Applications and High-Volume Use Cases
Neway’s high-volume die casting services are used by global OEMs across sectors including:
Automotive: EV battery cases, housings, transmission parts, structural brackets
Aerospace: Lightweight frames, sensor housings, heat management modules
Industrial Equipment: Hydraulic bodies, motor casings, gear enclosures
Electronics: Heat sinks, RF/EMI enclosures, device frames
Appliances: High-detail exterior covers, control panel housings, internal structures
With scalable production from 10,000 units to over 1 million parts per year, we help companies fulfill complex, multi-model part requirements reliably and economically.
Scalable Mass Production Starts with Expert Engineering
What sets Neway apart is not just capacity—but the ability to engineer every part for manufacturability, cost-efficiency, and performance. Our team works with clients to optimize part designs for casting, select ideal alloys, and ensure tooling longevity across high cycle volumes.
We also support Design for Manufacturability (DFM) reviews, prototyping, and engineering consultation to help streamline the transition from concept to mass production.
If you're looking for a trusted partner to scale custom metal parts with precision and efficiency, Neway is ready to help you move forward.
Contact us today to request a quote or schedule a project evaluation.
Frequently Asked Questions
What is the minimum quantity required for die casting mass production?
How do you ensure quality control across large-scale production runs?
Can I get prototypes before moving into mass production?
What are the typical lead times for full-scale die casting production?
What options are available for post-processing and finishing of die cast parts?
