Gravity Die Casting Foundry

SIPX provides superior quality gravity die casting parts and components for a wide range of industries including automotive, food dairy, machinery, medical, plumbing, watering, mining, petrochemical, electrical, energy and others. Whether you want to produce medium or high quantities, nothing is more cost-effective than gravity die casting. However, if you are producing a low volume of parts, it will cost you more due to the increased initial cost of the die itself.

What is Gravity Die Casting

Gravity Die Casting is a semi-permanent or permanent mould casting process, where the molten metal is poured from a vessel into the mould with no force other than gravity, filling can be controlled by tilting the die angles. Both metal and sand cores can be incorporated into the component for greater complexity of design. This method allows a single set of dies to be reused indefinitely to produce the same part.

It is perfect for creating repeatable medium- and high-volume parts, and it is different from high-pressure die casting and is used for parts that are slightly heavier, larger in size, and have higher structural requirements than high pressure die casting. 

Gravity die casting requires lower mould cost than high pressure die casting, but more durable than sand casting by using a steel mould. The mould is a permanent form that consists of two halves.

Why Choose SIPX

With over 10 years of experience, Sipx is well versed in this field. Yes, you are dealing with masters. You can trust us with your needs and expectations.

You will save 20-30% of the cost because of our excellent production capacity. Furthermore, we only insist on making high-quality casting products.

  • Rapid Prototyping
  • One-Stop Services Supplier, On-demand manufacturing
  • ISO16949 Certificated
  • Strict Quality Control System

    *Your details will be kept strictly confidential with us.

    How Are Gravity Die Castings Made?

    sand core making

    1. Sand Core Making

    Resin and sand mixture is poured into a steel mold, the mold is heated to speed up the fuse of the resin sand mixture. When it is solidified, the sand core is placed in the cavity of the casting die for next step.

    die release coating

    2. Coating Die Release Agent

    This step involves heating the mold and sprayed with a refractory coating that aids in release. The coating both helps control the temperature of the die during manufacture and it also assists in the removal of the casting.

    molten metal pouring

    3. Pouring the Metal

    The molten alloy is poured into the mold, which is done by manual (in some cases a automatic machine can be used). The designated runner that ensures the liquid fills the cavity completely, preventing turbulence in the hardened part as well as pores.

    remove the parts

    4. Releasing the Part

    The part will cool due to the heat sinking effect of the die. When it has cooled enough, the operator or a machine opens the die to remove the part.

    shakeout and trimming

    5. Shakeout and Casting Removal

    The castings are placed in a shakeout machine, the sand core is removed by vibration. The gates and runners are then trimmed and  blast cleaned (if required) prior to despatch to the customer.

    Advantages of Gravity Die Casting

    Gravity die casting is desirable for its lack of reliance on high pressure as well as the versatility of materials with which it can produce castings. Here are some of its advantages:

    • Tight tolerances allow for excellent accuracy in finished parts.
    • Highly repeatable process.
    • The surface of gravity die cast parts is smoother than those produced with sand casting.
    • The parts with excellent mechanical properties and T6 heat treatment can also be applied to improve the properties.
    • Insertable sand core parts can be pre-formed and used to create reverse draft interior pockets.
    • The part can be made with internal inserts and steel pins.
    • Less investment in mould compared with pressure die casting process.
    • Large range of alloy choices.

    Is Gravity Die Casting Cost-Effective?

    Gravity die casting is cost-effective for medium- and high-production runs of products. The cost per unit increases when a low volume of parts is required due to the high initial capital cost of the die itself.

    A die is machined from solid steel and, due to the irregular and customized design of each one, it can be quite expensive. The tolerances of the die are typically quite stringent. Furthermore, there is the cost of the alloys, the machine shop setup, lubricant and production time. With high-volume production output, these costs are spread over many units and become increasingly lower. The shape retention and quick heat dissipation of the die make it dependable for repeated use.

    For manufacturers requiring a high volume of parts, gravity die casting is one of the best options available. It allows for reliable, repeatable parts that provide consistent quality as well as a broad selection of different metal alloys to choose from. Aluminum gravity die casting is one of the most popular and versatile choices for manufacturers needing strength, conductivity, thin walls, low weight, corrosion resistance and good mechanical properties. It is also a relatively affordable alloy to choose.

    What Products Are Produced With This Method?

    Most products made with gravity die casting are aluminum and can weigh anywhere from around 1 lb. to well over 100 lbs. The possibilities for different products are numerous:

    • Automotive parts: Engine components, gearbox cases, componentry for cylinders, electronic equipment and structural equipment
    • Lighting: Electronic components for lighting, control panels, fixtures, housing and components
    • Defense: Military sectors are in need of reproducible parts for weaponry, surveillance and more
    • Electronics: Hi-fi equipment, consumer electronics, housing, tools and more
    • Medical: Surgical equipment, gearboxes and hospital equipment

    Materials

    Material Tensile Strength (Mpa) Thermal Conductivity (W/mK) Features
    Aluminum A380 325 96 Best combination of mechanical, casting, and the thermal properties.
    Excellent fluidity, pressure tightness, and resistance to hot cracking.
    Widely used for engine brackets, hand tools, electronic equipment chassis, gearbox cases, and household furniture.
    Aluminum A360 317 113 Excellent pressure tightness and fluidity.
    High corrosion resistance.
    High strength in elevated temperatures.
    Aluminum 413 295 121 Good combination of casting, mechanical, and thermal properties.
    Excellent fluidity, pressure tightness, and resistance to hot cracking.
    Aluminum 383 310 96 Often used for highly intricate components.
    Good corrosion resistance, lightweight.
    Good combination of casting, mechanical, and dimension stability.
    Aluminum B390 317 134 High hardness and good wear resistance.
    Suitable for internal combustion engine pistons, cylinder bodies for compressors, and brakes.
    Aluminum A413 290 121 Excellent pressure tightness.
    Good choice for hydraulic cylinders.
    Suitable for gravity die casting intricate components.