High-Pressure
Die Castings.
Designed with precision. Delivered with speed.
Precision aluminum, zinc & magnesium die castings — globally sourced and program-managed. MES doesn’t just source the part. We manage the tooling, quality, and supply chain that delivers it.
What is die casting?
Die casting forces molten metal under pressure into a reusable steel mold — called a die. It produces high volumes of dimensionally accurate metal parts with excellent surface finish and thin walls, making it one of the most cost-effective processes for medium-to-high volume aluminum, zinc, and magnesium components.
Because the steel die can be reused for hundreds of thousands of cycles, die casting delivers a low per-part cost at scale — with the repeatability that demanding automotive, lighting, and electrical programs require.
Die casting processes we support
High-pressure die casting
Molten metal is injected into the die at high speed and pressure. The most common process for automotive, electrical, and lighting components.
High-volume, thin-walled, complex aluminum and zinc parts where dimensional repeatability matters.
Low-pressure die casting
Molten metal is pushed upward into the die under controlled, lower pressure for superior internal soundness.
Larger structural parts where porosity control and mechanical strength are critical — suspension and structural housings.
Use HPDC for thin walls, fine detail, and high volumes. Use LPDC for thicker, structurally loaded parts that need superior internal soundness. MES matches the process, alloy, and supplier to your part’s geometry, volume, and application — before tooling is cut.
Alloys we source
Alloy selection is driven by part function, weight target, corrosion exposure, thermal requirements, and cost. MES evaluates all of these with your team during quoting and tooling — not after.
- A380: The most widely used die casting alloy — strong general-purpose choice with good strength, thermal conductivity, and castability.
- A383 / ADC12: Improved fill for thin-walled and complex parts. Common in electronics and lighting.
- A360: Higher corrosion resistance and better performance at elevated temperatures.
- Zamak 3 & Zamak 5: Excellent for thin walls, fine detail, plating, and tight tolerances — at lower melt temperatures and longer die life.
- AZ91D: The lightest structural casting alloy — used where weight reduction is the priority.
Alloy selection evaluated during quoting & tooling · matched to function, weight, corrosion & cost
Design & engineering support (DFM)
Our engineers support design for manufacturability from concept through launch — reducing redesigns and hitting your specifications the first time. Typical guidance we provide:
Send us your part for a DFM reviewWall thickness
Uniform walls (commonly 0.06″–0.20″ / 1.5–5 mm depending on alloy and part size) reduce porosity and shrinkage.
Draft angles
Adequate draft on all vertical walls allows clean ejection and longer die life.
Tolerances
±0.005″ capability on critical datums and mating surfaces; tighter tolerances achieved through secondary machining.
Fillets and radii
Generous internal radii reduce stress concentration and improve metal flow.
Moldflow analysis
We run flow simulation before steel is cut to catch fill, porosity, and shrink issues early.
Secondary operations
MES manages the full part — not just the casting. One partner delivers the finished, inspected, ready-to-install component.
Quality & inspection
MES embeds engineers and quality specialists at supplier facilities — measuring quality at every production stage, not just at final inspection.
- Co-managed tooling builds
- PPAP submission & management
- CMM dimensional inspection
- X-ray & ultrasonic inspection
- Leak testing for sealed parts
- On-site embedded engineers
The MES difference
- Find a supplier and place the order
- React when things go wrong
- Hand you the supply chain to manage
- Catch quality issues after delivery
- Match part complexity to the right geography and supplier
- Manage tooling, PPAP, and quality proactively
- Build redundancy into your supply chain
- Own execution from RFQ through delivery and inventory
- Keep engineers on-site at supplier facilities
Every account gets a dedicated planner and supply chain specialist who manage forecasts, inventory, and on-time delivery.
Globally sourced die castings
MES maintains active supplier relationships across the key manufacturing hubs of China, India, Mexico, and Vietnam. This diverse sourcing strategy lets us optimize lead times, cost, and logistics for every program — and enables China+1 strategies for customers diversifying risk without sacrificing cost or quality.
High-volume
Parts across all tonnage ranges
Nearshoring
Duty-free USMCA access
Cost
advantageScaling precision and quality
Diversification
Supply chain resilience
Aluminum die castings by tonnage & country
| Tonnage | China | India | Mexico | Vietnam | Total |
|---|---|---|---|---|---|
| 100–200T | 321 | 33 | 33 | 11 | 398 |
| 201–400T | 433 | 41 | 63 | 5 | 542 |
| 401–600T | 89 | 21 | 9 | 3 | 122 |
| 601–800T | 132 | 22 | 10 | 9 | 173 |
| 801–1,000T | 80 | 5 | 6 | 2 | 93 |
| 1,001–1,200T | 68 | — | 9 | — | 77 |
| 1,201–1,600T | 60 | 1 | 1 | — | 62 |
| 1,601–1,800T | 73 | — | — | — | 73 |
| 2,000–2,500T | 18 | — | — | — | 18 |
| Grand total | 1,274 | 123 | 131 | 30 | 1,558 |
Our 4,400-ton press, running at full capacity
MES manages die casting programs across the full tonnage spectrum — from 50-ton precision parts to large structural castings on 4,400-ton presses. The largest press class in our network, producing structural aluminum castings up to 2,500T for automotive, energy, and industrial applications.
Industries we serve
Automotive, Hybrids & EV
Lightweight aluminum die castings for motor housings and battery enclosures, with leak testing and X-ray/ultrasonic inspection for safety components.
Commercial Lighting
Die cast aluminum housings and heat sinks optimized for thermal management in LED, industrial, and architectural lighting.
Electrical & Energy
Components for switchgear, circuit breakers, conduit fittings, and energy distribution where dimensional accuracy is non-negotiable.
Construction & Agriculture
Durable die cast parts for heavy equipment and demanding outdoor environments — from hydraulic housings to structural brackets.
Robotics & Automation
Die cast components for robotic arms, servo housings, grippers, and automated system enclosures.
Companies including Eaton, Acuity Brands, Honda, and Cooper Lighting rely on MES to consolidate their die casting supply chain.
Frequently asked questions
High-pressure die casting forces molten metal into a steel die at high speed and pressure, making it ideal for high-volume, thin-walled, complex aluminum or zinc parts. Low-pressure die casting uses controlled upward pressure at lower speeds, suited for larger structural components where porosity control and surface finish are critical.
MES embeds engineers and quality specialists directly at supplier facilities, not just at final inspection. We co-manage tooling builds, conduct Moldflow analysis before production begins, and oversee PPAP submissions. Every customer receives a dedicated planner who monitors inventory, forecasts, and delivery in real time.
Lead times vary by part complexity, tooling requirements, and geography, but MES proactively manages tooling builds to prevent the 8–12 week delays that commonly occur when programs are under-managed. Our experience across 1,500+ die cast parts means we anticipate and prevent the delays most suppliers discover too late.
Yes. MES actively designs China+1 sourcing strategies with established supplier networks in India, Mexico, and Vietnam. We help customers diversify risk without sacrificing cost or quality, aligning sourcing decisions to part complexity, logistics, and tariff environment.
MES works exclusively with IATF 16949 and ISO 9001 certified suppliers. For automotive and e-mobility applications, IATF 16949 certification ensures suppliers meet the rigorous process and quality management requirements of the automotive supply chain.
MES primarily sources aluminum (A380, A383/ADC12, A360) and zinc (Zamak series) alloys, with magnesium and copper-based alloys for specialty applications. Alloy selection is driven by part function, weight target, corrosion requirements, and cost, all evaluated during quoting and tooling.
MES sources across a 50 to 4,400 ton press range, covering everything from small precision components to large structural castings up to 2,500 tons of clamping force.
Get a die casting quote
Send us your part drawing or 3D model and a dedicated specialist will match it to the right alloy, process, and supplier.