Custom Die Casting Services -From Your Drawing to Your Dock

KastMfg provides a complete custom die casting service for OEM, Tier 1, and industrial customers worldwide. From your first inquiry through DFM review, tooling fabrication, first article sampling, production, and logistics -one team, one facility, one point of accountability.

We have been producing custom die casting components for over 20 years. That experience means our engineers have encountered nearly every casting challenge and every customer requirement type -from simple single-cavity aluminum brackets to complex multi-slide zinc precision components with electroplated decorative surfaces.

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What "Custom" Means at KastMfg

Custom die casting at KastMfg is not a catalog product with your logo on it. It is:

• Your geometry -produced to your 2D drawing or 3D CAD model, with your tolerances
• Your alloy -we recommend the optimal alloy for your application, or work to your specification
• Your quality requirements -ISO, IATF 16949, PPAP, or your own internal acceptance criteria
• Your schedule -tooling and production timelines defined and committed at program launch

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Our Service Model

Free DFM Review -Before You Commit to Tooling

Every KastMfg inquiry begins with a Design for Manufacturability (DFM) review at no charge. A project engineer reviews your drawing for:

• Draft angles -surfaces parallel to die opening must have sufficient taper for ejection
• Wall thickness -uniform thickness prevents shrinkage porosity and warpage
• Undercuts -features requiring slides are identified and costed
• Tolerances -we confirm which tolerances are achievable as-cast vs. requiring post-machining
• Gating and overflow -gate location affects surface appearance; overflows capture cold metal

You receive a written DFM report with specific recommendations. If design changes can reduce tooling cost or improve casting quality, we explain exactly what to change and why. This report has saved customers thousands of dollars in tooling changes after the fact.

In-House Tooling -No Subcontracting

KastMfg designs and fabricates all tooling in our own tool shop. We do not outsource die fabrication. This means:

• Faster lead times -no coordination delays with external tooling shops
• Better quality -the same team that designs your casting advises on the die design
• Full traceability -complete die drawings, material certs, and maintenance records maintained in-house
• Direct control -if a trial shot reveals a fill problem, our tooling team modifies the die on-site the same day

Tooling timeline:

• Prototype die (P20 steel, single cavity): 3- weeks
• Production die (H13 steel, single cavity): 5- weeks
• Multi-cavity or complex slide tools: 6-10 weeks

First Article and PPAP

Upon tooling completion, we produce a defined quantity of first article samples and submit a full inspection report:

• 100% dimensional layout to drawing (all dimensions, all GD&T callouts)
• Material certification (alloy chemistry, mechanical properties)
• Process capability study (Cpk >=1.67 on all critical features)
• Functional test results (pressure test, leak test) if applicable
• PPAP package at Level 1- as specified

Nothing moves to production without your formal approval of the first article.

Production with SPC

Approved programs transition to production with all parameters documented and locked. Key process parameters -injection velocity, peak pressure, die temperature, cycle time -are logged every shot. Critical dimensions are measured at defined intervals with SPC charts maintained throughout the run.

Secondary Operations and Delivery

Parts proceed through CNC machining, surface finishing, and assembly as required by your drawing. They are then packaged to your specification -bulk, tray, individually wrapped, or custom foam -and shipped by ocean or air to your destination.

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Industries and Part Types

Industry	Representative Custom Parts
Automotive / EV	Motor housings, battery tray members, gearbox covers, caliper bodies
Industrial Machinery	Hydraulic manifolds, pump housings, motor end shields, compressor crankcases
Electronics	Heat sinks, RF shielding enclosures, server chassis components, 5G housings
LED Lighting	Streetlight bodies, high-bay housing, floodlight enclosures
Consumer Products	Power tool housings, hardware fittings, appliance components

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What to Send Us

To get started, send any of the following to yaoqingpu1983@gmail.com:

• 3D CAD file (STEP, IGES, SolidWorks, PTC) -preferred
• 2D engineering drawing (PDF or DWG) with tolerances
• Physical sample part for reverse engineering
• Sketch or concept -we can provide DFM and design-for-casting advice even at concept stage

Include your target volume, required alloy or application description, and any quality or certification requirements. We do the rest.

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Frequently Asked Questions

Can you handle low-volume prototype programs?

Yes. KastMfg regularly produces prototype programs of 50-100 pieces using P20 prototype tooling at lower tooling cost. Prototype tooling produces the same alloy in the same die casting process -unlike 3D-printed or machined prototypes, die cast prototypes represent the actual production process and material.

What happens if production parts don't meet my drawing?

KastMfg provides a written non-conformance response within 24 hours of any reported quality issue. We contain the affected inventory, investigate root cause (8D), implement corrective action, and resubmit conforming parts. We do not pass quality problems to the customer.

Can you take over a program currently produced elsewhere?

Yes. We onboard transferred programs regularly. Provide existing tooling for inspection and refurbishment assessment, or supply drawings for new tooling. We qualify the process to your existing PPAP or FAI standard.

Do you have experience with dual-source supply chain requirements?

Yes. Some customers require KastMfg to qualify as a second source while maintaining an existing primary supplier. We support this process with full PPAP submissions and are accustomed to the technical coordination that dual-source qualification requires.

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Start your custom program: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China