Die Casting Cost -What Drives Price & How to Get an Accurate Quote | KastMfg
What determines die casting part cost: material, cycle time, secondary operations, tooling amortization, and quality overhead. Typical price ranges and how to structure an RFQ to get a meaningful quote.
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Die Casting Cost -What Drives Price and What to Expect
Die casting part cost is one of the most volume-sensitive pricing structures in manufacturing. The same part can cost $0.50 at one million pieces per year or $15.00 at five hundred pieces per year -a 30x difference driven entirely by tooling amortization and setup efficiency. Understanding the cost components helps buyers evaluate quotes accurately and identify where cost reduction is possible.
The Five Cost Components
1. Material Cost
The most straightforward component: weight of metal in the finished part x alloy price per kg.
| Alloy | Approximate Market Price (2,024-2,025) | Finished Part Density |
|---|---|---|
| A380 aluminum | $2.20-2.60/kg | 2.71 g/cm³ |
| ADC12 aluminum | $2.20-2.65/kg | 2.74 g/cm³ |
| Zamak 3 zinc | $2.80-3.40/kg | 6.60 g/cm³ |
| Zamak 5 zinc | $2.85-3.50/kg | 6.60 g/cm³ |
| AZ91D magnesium | $3.50-4.50/kg | 1.81 g/cm³ |
Material cost as a fraction of total part cost: 15-20% depending on part weight and production volume. Higher at low volume (other components are fixed); lower at high volume.
Note: Die casting yield is 70-75% -the remaining 15-20% is gates, runners, and flash returned to the furnace as recycled metal. Quoted material cost reflects net part weight, not shot weight.
2. Machine Time (Cycle Time x Machine Rate)
Cycle time x machine rate per hour = machine cost per part.
| Machine Size | Typical Hourly Rate | Typical Aluminum Cycle Time | Machine Cost Per Part |
|---|---|---|---|
| 160T | $60-70/hr | 35-40 s | $0.58-1.11 |
| 400T | $85-110/hr | 45-50 s | $1.06-2.14 |
| 800T | $120-160/hr | 60-70 s | $2.00-4.00 |
| 1,600T | $180-240/hr | 90-150 s | $4.50-10.00 |
For zinc hot-chamber (smaller machines, faster cycles):
| Machine Size | Typical Hourly Rate | Typical Zinc Cycle Time | Machine Cost Per Part |
|---|---|---|---|
| 80T | $50-55/hr | 18-25 s | $0.25-0.45 |
| 160T | $60-70/hr | 20-25 s | $0.33-0.78 |
3. Secondary Operations
Post-casting operations add cost proportional to their cycle time and equipment rate:
| Operation | Typical Cost Addition Per Part |
|---|---|
| Trimming (trim die) | $0.05-0.30 |
| CNC machining (simple) | $0.50-3.00 |
| CNC machining (complex, 5-axis) | $2.00-15.00 |
| Shot blasting | $0.05-0.20 |
| Powder coating | $0.80-3.00 |
| Type II anodizing | $0.50-2.00 |
| Type III hard anodizing | $1.00-4.00 |
| E-coating | $0.50-2.50 |
| Pressure testing (100%) | $0.20-0.80 |
| Assembly (inserts, bearings) | $0.30-3.00 |
4. Tooling Amortization
Tooling cost divided by total lifetime production quantity:
Tooling amortization per part = Tooling cost / Lifetime quantity
Examples:
- $15,000 tooling / 100,000 pieces = $0.15/part
- $15,000 tooling / 1,000,000 pieces = $0.015/part
- $40,000 tooling / 200,000 pieces = $0.20/part
Tooling amortization is the most volume-sensitive cost component. At low volume it dominates total cost; at high volume it becomes negligible.
5. Quality and Overhead
Quality inspection, SPC data collection, documentation, and overhead: typically 8-15% of direct cost.
Indicative Price Ranges
These ranges reflect KastMfg pricing -actual prices depend on specific geometry, tolerances, and secondary operations.
| Part Type | Annual Volume | Indicative Unit Price (USD) |
|---|---|---|
| Small aluminum bracket, as-cast | 10,000/yr | $1.50-4.00 |
| Small aluminum bracket, as-cast | 100,000/yr | $0.80-2.00 |
| Medium aluminum housing (machined) | 10,000/yr | $5.00-15.00 |
| Medium aluminum housing (machined) | 50,000/yr | $3.00-8.00 |
| Large aluminum structural casting | 20,000/yr | $8.00-25.00 |
| Small zinc hardware, as-cast | 100,000/yr | $0.50-2.00 |
| Small zinc hardware, chrome plated | 100,000/yr | $1.50-4.00 |
| Hydraulic valve body (machined, tested) | 5,000/yr | $12.00-30.00 |
| Hydraulic valve body (machined, tested) | 30,000/yr | $6.00-15.00 |
What Makes Quotes Incomparable
When getting quotes from multiple suppliers, the following variations make comparison meaningless without adjustment:
Scope differences: Supplier A quotes raw casting; Supplier B quotes machined and finished. Unit prices are incomparable -specify complete scope.
Volume point differences: Both suppliers quote the same part but at different annual volumes. Price at 10,000/year is not comparable to price at 50,000/year.
Alloy differences: A380 and ADC12 are close; A380 and A360 have different material costs. Verify both suppliers are quoting the same alloy.
Tooling ownership differences: Some suppliers quote low unit price but retain tooling ownership, preventing transfer. Others include tooling ownership with no strings. The total cost of ownership differs significantly.
How to Get a Meaningful Quote from KastMfg
- Submit a complete drawing (STEP + 2D PDF with all tolerances)
- State the annual volume you want the unit price based on
- List all secondary operations required (machining, surface finish, testing)
- Specify the alloy or describe the application (we recommend)
- State any quality certifications required (PPAP level, material cert format)
KastMfg returns a quotation within 48 business hours with: itemized tooling cost, unit price at three volume breaks, lead time, and a DFM note identifying any castability concerns.
Get a quote within 48 hours: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
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