Prototypes and low-volume production in light metal

We specialise in producing prototypes and low-volume production series in light metal and use a variety of manufacturing methods including high-pressure die casting, machining from block (MFB) and investment casting. In addition, we have a wide range of finishing options and in close dialogue with the customer, we find the manufacturing process that best meets cost, quantity and finish requirements.

High-pressure die-casting of prototypes and low-volume production

We are experts in high pressure die casting techincal parts in aluminium, magnesium and zinc. With a high capacity, we can die cast parts up to 21.8 kg with a clamping force of up to 1350 T and parts with wall thicknesses down to 1 mm. With our hot chamber zinc machine, we can die parts up to 3.4 kg with great speed and precision. All our high pressure die casting machines are fully equipped with peripheral equipment to produce consistent light metal parts.

Materials and alloys

We stock a wide range of light metals for high pressure die casting and always help ensure that the material we recommend is the right choice for you.

Aluminium is the most commonly used material. It's easy to work with and an inexpensive material. Also included is Duralcan®, which is a very durable material characterised by high tensile strength, yield strength and tensile strength. Our most commonly used alloys include:
- Aluminium EN AC 44300 - AlSi12(Fe) (a). For complex shapes including thin wall thicknesses. Good corrosion resistance and relatively good mechanical properties. Density: 2.7kg/dm3
- Aluminium EN AC 46000 - AlSi9Cu3. Good alloy for all-round use, for complex shapes and for relatively thin wall thicknesses. Relatively good mechanical properties. Density: 2.7kg/dm3
- Aluminium EN AC 47100 - AlSi12Cu1(Fe). For complex shapes and relatively thin wall thicknesses. Relatively good corrosion resistance. Density: 2.7kg/dm3
- Aluminium EN AC 42100 - AlSi7Mg0.3. For investment casting. Good strength properties. Density: 2.7kg/dm3
- We can also cast in other aluminium alloys.
Magnesium gives a really nice finish and is also lighter than aluminium. Therefore, it is used in products where a lower total weight is required. Our most commonly used alloy is:
- Magnesium AZ 91 - A lightweight material with a beautiful finish. Often used in products where a lower total weight is desired. Density: 1.8kg/dm3
Zinc is good for items that require fine tolerances and smaller wall thicknesses. It is durable, in some cases stronger than aluminium, and is therefore often used for fittings, hinges, etc. Our most commonly used alloy is:
- Zinc ZA8 - Good for items that require fine tolerances and smaller wall thicknesses. The material is durable and often used for fittings, hinges, etc. Density: 6.7kg/dm3

High-pressure die-casting in aluminium, magnesium and zinc

Other manufacturing methods and post-processing

Machined from block

In our state-of-the-art CNC department, we offer this method where light metal parts are milled directly from the block. This is perfect for complicated parts with fine tolerances, small piece counts and dropout samples. The method is often used for prototyping.

Investment casting

We recommend choosing high pressure die casting and machined from block for light metal prototypes, but in rare cases also investment casting if the part is low volume and complicated to manufacture with traditional casting methods.

Post-processing

We manage a range of post-processing options for your light metal part to achieve the exact finish or tolerances you want, including heat treatment, CNC machining, impregnation, various surface treatments and painting. We handle all post-processing, so you're guaranteed a fast delivery and seamless handover.

Your one-stop shop

With in-house product development, tool making, plastic, light metal and EPS/EPP moulding, metrology and assembly, we can help with all necessary processes. You are guaranteed a short lead time, high flexibility and competitive prices. Idé-Pro is your partner from idea to prototype, product and production.

Get a quote