Can die cast parts meet AS9100 or FAA quality standards?

Can Die Cast Parts Meet AS9100 or FAA Quality Standards?

Overview of Aerospace Quality Standards

Yes, die cast parts can meet AS9100 and FAA quality standards when manufactured under controlled processes and verified with certified inspections. These standards do not exclude die casting as a process; rather, they define the required quality management system (QMS) and part performance criteria necessary for aerospace components. At Neway, our casting operations are designed to support precision manufacturing with full traceability, rigorous inspection, and material certification aligned with aerospace requirements.

AS9100 Compliance for Die Casting

AS9100 is the internationally recognized QMS standard for aerospace and defense manufacturers. Die cast parts can meet AS9100 compliance when:

• The die casting facility operates under an AS9100-certified QMS

• All critical features and tolerances are validated using calibrated inspection tools

• Material certifications and casting alloy traceability are provided

• Statistical process control (SPC), FAI (First Article Inspection), and PPAP documentation are maintained

AS9100 does not restrict the use of die casting—it ensures that parts consistently meet dimensional, mechanical, and documentation requirements defined by the customer or application.

FAA Requirements and Die Cast Parts

The Federal Aviation Administration (FAA) evaluates parts based on airworthiness, material integrity, and process consistency. For a die cast part to be FAA-approved (such as through PMA or TSO routes), it must:

• Be manufactured with FAA-compliant design and documentation

• Use qualified materials with proven mechanical performance

• Undergo dimensional inspection, non-destructive testing (e.g., X-ray for porosity), and functional validation

• Be produced in a controlled environment with process traceability and part serialization when required

Die casting is often used for non-structural aerospace parts such as housings, brackets, enclosures, or interior fittings, where weight, complexity, and cost are optimized while still maintaining compliance with aerospace-grade quality.

Recommended Die Casting and Quality Services for Aerospace Compliance

Neway supports aerospace projects through:

• Certified Die Casting

  • Aluminum Die Casting: Tight-tolerance casting of non-structural aerospace parts.

  • Casting Materials: Use of qualified aerospace-grade aluminum alloys such as A356 and AlSi10Mg.

• Quality Control and Compliance

  • Die Castings Inspection: X-ray, CMM, pressure, and dimensional testing to validate part integrity.

  • Post Machining: Achieve precision tolerances required by aerospace standards.

• Design and Documentation Support

  • Die Casting Engineering: FAI, DFM, and compliance documentation support.

  • One-Stop Service: Fully integrated workflow for traceability, inspection, and aerospace documentation.