Large Aluminum Die Casting - Up to 1,600T Capability

Large aluminum die casting covers parts roughly above 5 kg shot weight - big enclosures, structural housings, battery trays, and frames that most die casters cannot run because their machines top out at 800 tons. KastMfg operates machines up to 1,600 tons clamping force, putting multi-kilogram aluminum castings into daily production rather than specialty territory.

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What Counts as "Large" in Die Casting

Class	Machine	Typical parts
Standard	280 to 800T	Small housings, brackets, hardware
Large	800 to 1,600T	Motor housings, gearbox cases, large enclosures
Very large / giga	4,000T and above	EV body structures (see giga casting)

Our 1,600T line covers the practical middle ground: parts up to roughly 15 to 20 kg shot weight and 800 mm envelope - large enough for most industrial and EV component programs, without the six-figure tooling economics of giga presses.

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Parts We Run on Large Machines

• EV and motor components: motor housings, inverter enclosures, controller cases (see EV die casting)
• Industrial housings: gearbox and reducer cases, pump and compressor bodies
• Electronics: large telecom chassis, 5G base station housings, server frames
• Lighting: flood light and high-bay housings with integrated heat sink fins
• Furniture and hardware: chair bases, table frames, equipment stands

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Engineering Realities of Large Castings

Large parts punish weak process control. Three things decide success:

1. Thermal balance. A 15 kg shot dumps enormous heat into the die. Conformal or well-zoned cooling channels keep cycle times at 90 to 150 seconds without hot spots that cause shrinkage porosity in thick sections.

2. Fill simulation. At this size, fill simulation (mold flow) is not optional. Gate location and overflow placement decide whether the far corners fill before the metal freezes. We simulate every large die before steel is cut - part of our die casting tooling process.

3. Machine lock-up. Flash on a 1,600T machine means real problems: projected area calculations must include margin, because a flashing die at this scale damages parting lines quickly.

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Alloy Choices for Large Parts

• A380 / ADC12: the default - best fill behavior for large thin-wall sections (A380 details)
• A383: when fins or very thin walls push fill limits (A383 details)
• A360: when corrosion resistance matters more than castability

For structural parts above this size class, or where full T6 is required, low pressure die casting with A356 is often the better process - we will tell you honestly at RFQ review.

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From Casting to Finished Part

Large castings almost always need secondary work, and doing it under one roof is where programs are won or lost:

• In-house CNC machining of datums, bores, and sealing faces (machining capability)
• Leak testing for pressure-tight housings - air decay and helium
• Impregnation for porosity sealing when the spec requires it
• Powder coating, e-coat, and surface finishing sized for large parts
• Export packaging and logistics with corrosion protection for sea freight

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RFQ Checklist for Large Castings

To quote a large part accurately in 48 hours, send:

1. 3D model (STEP) + 2D drawing with critical tolerances
2. Annual volume and ramp plan
3. Alloy and any leak-tightness requirement (test pressure, allowable leak rate)
4. Surface finish and operating environment

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Related Pages

• custom die casting - full service scope
• die casting capabilities - machine list and capacity
• aluminum die casting - alloys and process
• vacuum die casting - for structural and T6 requirements

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Large part inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China