High-Pressure Die-Casting

High-pressure die-casting is a quick process that creates metal components with complex shapes. The process is similar to metal injection molding, but unlike MIM it is suitable for metals with low melting points where no sintering is required. There are three basic steps to the process:

  1. Molten metal is poured into the reservoir
  2. A plunger forces the liquid under high pressure into a die cavity
  3. The pressure is maintained until the metal solidifies, and small ejector pins push the parts out of the die

This process is often used to create the surface finish on matchbox cars. Its ability to create complex details for small sections and thin walls allows for a fast process. However, the tooling is expensive, therefore the process is most fitting for very high production volumes and the parts are not guaranteed to have great structural strength (fitting for matchbox toy cars).