Aluminum
Die Cast Parts

That Perform

Aluminum Die Casting

Why Choose PHB for Aluminum Die Casting?

  • From design concept to production and packaging PHB is a world leader in die casting, with clients ranging from automobile manufacturers to the U.S. military.
  • PHB solves problems. Our clients value our ability to turn complex design specifications into reality.
  • PHB handles all aspects of aluminum die casting from mold design and testing, to aluminum component manufacturing, finishing, and packaging.
With over 100 years of experience in aluminum die casting, PHB has evolved into a world class leader utilizing its technological wherewithal and skilled professionals to manufacture high quality die castings internationally in the most cost effective manner. Timely delivery is protocol for us, so you can rest assured your shipment will arrive on time.

Aluminum Die Casting Capabilities

Our 58 presses range in size from 250 ton to 2000 ton producing aluminum die casting components for low and high volume production programs. PHB provides high pressure die casting, and a range of other die casting processes. Process monitoring, press side imaging, robotics, MAGMAsoft® flow simulation, perpetual tooling and tool maintenance programs are utilized to extend tool life, reduce cycle times, reduce costs and provide high quality die castings. From part conception and prototyping through assembled finished production, PHB can provide, under one central umbrella, the integrated services required to be your complete global manufacturing resource.

MagmaSoft® Aluminum Mold Flow Testing

PHB uses the internationally recognized MAGMAsoft® simulation technology to optimize tool design and aluminum casting quality. MAGMAsoft® simulation capabilities provide a better understanding of aluminum injection mold filling, high pressure aluminum die casting, solidification, mechanical properties, thermal stresses and distortions, and much more. Fully menu-driven with an integrated solid modeler, CASD interfaces, and extensive databases, MAGMAsoft® provides a complete solution for design, production, and quality departments. Read More About MAGMAsoft®

Prototyping of Aluminum Parts

PHB can provide components and assemblies in prototyping and low-volume production quantities using a multitude of methods including but not limited to:

  • Plaster Injection Mold Castings
  • CNC Machining and Hog-outs
  • Direct Metal Laser Sintering (DMLS)
  • P-20 Tooling

Aluminum Casting Alloys

Aluminum die casting alloys are lightweight and posses high dimensional stability for complex part geometries and thin walls. Aluminum has good corrosion resistance and mechanical properties as well as high thermal and electrical conductivity, making it a good alloy for die casting.

Our Alloys Include:
  • Aluminum: 360, 380, 383 and 413
  • Zinc-Aluminum: ZA-8, ZA-12 and ZA-27

Aluminum Surface Finishing

PHB will manage customer finishing requirements to ensure parts meet specifications in both a timely and cost effective manner.

Our Aluminum Surface finishing includes but is not limited to:
  • Powder Coating (electrostatic application)
  • Wet Paint
  • Chromate
  • E-Coat
  • Electroless Nickel
  • Chrome
  • Silk Screening and Stenciling
  • EMI/RFI Shielding
  • Surface Conditioning (shot and bead blasting)

Our Manufacturing Packaging Process

PHB offers a variety of packaging options for our customers. We can provide packaging layered or by cell. We cater to each individual market all across the globe, and understand that we may have to create something just for you. That’s why we also offer custom designed returnable cardboard or plastic packaging.

Whether you are in the concept stage or ready for production, PHB is ready to help.

Aluminum Die Cast Part Design Case Study

aluminum die cast part design

the problem

A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.

the solution

The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.

choose phb for your aluminum die casting needs today

aluminum die casting gallery