Aluminum Die Cast Structural Brackets & Mounts
Aluminum die cast structural brackets from 0.05 to 5 kg: engine and motor mounts, suspension nodes, and electronics brackets with T6 when required.
Production Capabilities
Component examples for aluminum die cast structural bracket
Component Range
Multiple die casting examples from this product family showing the scope of geometries, sizes, and features produced.
Feature Detail
Close-up views of critical features including threads, sealing faces, ribs, fins, bores, and mounting points.
Structural brackets in aluminum die casting span a wide performance range -from simple cable clips at cents per part to safety-critical suspension mounting brackets with IATF 16949 PPAP requirements. All share the combination of structural load, dimensional interfaces, and cost pressure that makes die casting the process of choice above certain volumes.
KastMfg produces structural brackets from 0.05 kg to 5 kg in aluminum, across 160T to 630T machines.
Structural Bracket Types
| Type | Weight | Alloy | Load Type |
|---|---|---|---|
| Engine mounting bracket | 0.5- kg | A380 | Static + vibration |
| Motor mounting bracket | 0.2-0.5 kg | A380 | Static + vibration |
| Suspension bracket | 0.3-1.2 kg | A380 T6 (VADC) | Dynamic, fatigue |
| Electronics mounting bracket | 0.05-1.5 kg | A380 | Static |
| Gearbox adapter flange | 0.3-0.5 kg | A380 | Torque, alignment |
| HVAC mounting bracket | 0.2-0.8 kg | A380 | Vibration |
| EV battery / motor bracket | 0.3- kg | A380 T6 (VADC) | Structural, crash |
Tolerances
| Feature | As-Cast | Post-Machined |
|---|---|---|
| Mounting hole position | +/-0.15-0.25 mm | +/-0.05-0.10 mm |
| Interface surface flatness | 0.05 mm | 0.02 mm |
| Hole diameter | +/-0.2 mm | H7: +/-0.010 mm |
When T6 is Required
T6 heat treatment is specified when the bracket is subject to dynamic fatigue loading (suspension, drivetrain) and the design requires yield strength above 250 MPa. A380 + T6 via VADC achieves ~300 MPa yield vs 159 MPa as-cast.
Most static mounting brackets use A380 as-cast or T5 -yield strength of 159-195 MPa is adequate and T6 cost is unnecessary.
Weight vs Alternative Processes
| Process | Weight (same geometry) | Tooling Cost | Unit Cost at 5,000/yr |
|---|---|---|---|
| Die cast A380 | Baseline | $12,000 | $2.50 |
| Machined from 6061 billet | +10% (solid vs near-net) | $0 | $18.00 |
| Stamped sheet steel | -0% (thinner, no taper) | $8,000 | $3.50 |
Die casting wins on per-unit cost above ~1,000 pieces lifetime versus machining, and on weight versus equivalent steel stampings.
Industries
Automotive (engine, EV, chassis) -> Industrial motors and drives -> Electronics chassis mounting -> HVAC equipment -> Agricultural machinery -> Construction equipment
Bracket inquiry: casting@kastdiecast.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
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CapabilityQuality Control
Review inspection workflow, traceability support, and process control standards before launch.
Process GuideDie Casting Process
See how casting, trimming, machining, finishing, and inspection fit together in production.
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