Manufacturing Capability
Aluminium
Casting.
Precision at Scale.
Three aluminium casting processes under one roof. Gravity Die Casting for complex medium-volume components. Low Pressure Die Casting for thin-wall structural integrity. High Pressure Die Casting for high-volume precision at speed.
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Process 01
Gravity Die Casting
Medium complexity · 0.1–25 kg · Sand cores for internal geometry · Low tooling cost vs HPDC
Process 02
Low Pressure Die Casting
Thin-wall structural · T6 heat-treatable · Low porosity · Wheel hubs, suspension
Process 03
High Pressure Die Casting
High volume · ±0.05mm tolerance · Ra 0.8–1.6 µm · 5,000–millions/year
Process Deep-Dive
Three Processes. One Right Answer for Your Component.
Selecting the wrong aluminium casting process costs money — wrong porosity spec, wrong tooling investment, wrong unit cost. Amsol's engineering review matches your component to the right process before any commitment.
Process Photography
Gravity Die Casting — Rajkot Facility
♦ GDC — Gravity Die Casting
Complex Geometry. Sand Cores. Pressure-Tight Integrity.
Molten aluminium poured under gravity into a permanent steel die. Unlike HPDC, GDC allows sand cores for complex internal passages — making it ideal for pump housings, manifold blocks, and components requiring pressure-tight internal geometry.
0.1–25kg
Weight Range
CT5–CT7
ISO 8062 Tolerance
Ra 3.2
Surface Finish (µm)
3mm
Min Wall Thickness
Process Photography
Low Pressure Die Casting — LPDC Line
▲ LPDC — Low Pressure Die Casting
Thin-Wall Structural. T6 Heat-Treatable. Minimal Porosity.
Metal rises from a sealed furnace below through a riser tube into the die cavity — controlled, turbulence-free fill that minimises oxide inclusions and porosity. The result: castings suitable for T5/T6 heat treatment and structural automotive applications where fatigue life is critical.
0.5–50kg
Weight Range
CT5–CT6
ISO 8062 Tolerance
2.5mm
Min Wall Thickness
T5/T6
Heat Treatment
Process Photography
High Pressure Die Casting — HPDC Production
■ HPDC — High Pressure Die Casting
Volume. Precision. Speed. The Benchmark for High-Volume Aluminium.
Molten aluminium injected at 700–1,400 bar into a hardened steel die in under 100ms. The result: components with ±0.05mm dimensional accuracy, Ra 0.8–1.6 µm surface finish, and wall thickness as thin as 1mm — produced at cycle times of 30–90 seconds per shot.
700–1400
Injection Pressure (bar)
±0.05mm
Dimensional Tolerance
1.0mm
Min Wall Thickness
25–1400T
Machine Range
Process Flow
From Drawing to Finished Casting — 5 Steps
Every aluminium casting at Amsol follows the same disciplined process — from DFM review before tooling commitment to CMM inspection before dispatch.
01
DFM & Process Review
Drawing reviewed for draft angles, wall thickness, core requirements, machining allowances. Process recommended: GDC / LPDC / HPDC.
02
Tooling Development
Die or permanent mould machined in tool steel. Trial casting run. First article dimensions verified before serial production begins.
03
Alloy Verification & Pour
Alloy composition verified by spectrometer before pouring. Melt degassed and cleaned. Casting cycle run under controlled parameters.
04
CNC Machining
As-cast components machined to final dimensions in-house on CNC/VMC/HMC. Bores, threads, faces, and critical interfaces machined under same roof.
05
CMM Inspection & Despatch
CMM verifies all critical dimensions. Spectrometer MTC attached. X-ray porosity check on LPDC/GDC pressure castings where specified.
Facility
The Amsol Aluminium Casting Floor
Five photo placeholders — replace with actual facility photography from the Amsol photography brief. Recommended: wide-angle facility shots, close-up component details, and inspection equipment.
Amsol Facility · Rajkot
Aluminium Die Casting Production Floor
Process
HPDC Machine — 1400T
Product
Precision HPDC Components
Quality
CMM Dimensional Inspection
Quality
Spectrometer — Alloy Verification
Material Capability
Aluminium Alloys — Full Range
Every alloy is verified by in-house optical emission spectrometer before pouring begins. Chemical composition confirmed per heat. MTC issued from Amsol's own measurement.
A380 / ADC12
ASTM A380
ProcessHPDC
Tensile317 MPa
Density2.71 g/cm³
CastabilityExcellent
Best general-purpose HPDC alloy. Most widely used. Excellent die fill and pressure tightness.
A356 / LM25
ASTM A356 · BS LM25
ProcessGDC · LPDC
Tensile (T6)228–283 MPa
Elongation5–8%
Heat TreatT5 / T6
Premium structural alloy. Heat-treatable to high strength. Wheel hubs, suspension, aerospace structural.
LM6 / A413
BS LM6 · ASTM A413
ProcessGDC · LPDC
Tensile160–190 MPa
CorrosionExcellent
CastabilityExcellent
Marine-grade alloy. Excellent seawater corrosion resistance. Marine fittings, pump housings, thin-wall complex castings.
A360 / LM24
ASTM A360 · BS LM24
ProcessHPDC
Tensile317 MPa
DuctilityBetter than A380
PressureTight castings
HPDC with better ductility and corrosion resistance than A380. Pressure-tight castings, electrical housings.
Process Selection
GDC vs LPDC vs HPDC — Choose the Right Process
The wrong process choice costs you money at the tooling stage or the unit cost stage. This comparison — plus Amsol's DFM engineering review — ensures the right decision before any commitment.
Gravity Die Casting
The flexible choice — complex geometry, sand cores, moderate volume
0.1–25kg
Weight Range
CT5–7
Tolerance
50–50K
Volume/Year
Low
Tooling Cost
Choose GDC When
Complex internal passages need sand cores
Volume is 50–50,000/year (HPDC tooling not justified)
Casting must be pressure-tight (pump housing, valve body)
Alloy is LM6 or LM25 (not suited to HPDC)
Get GDC Quote →
Low Pressure Die Casting
Structural integrity — thin wall, heat-treatable, low porosity
0.5–50kg
Weight Range
CT5–6
Tolerance
500–100K
Volume/Year
T5/T6
Heat Treatment
Choose LPDC When
Component is structural — fatigue life and strength are critical
T6 heat treatment is required for high strength
Wall thickness is thin (2.5mm achievable)
Component needs to be welded after casting
Get LPDC Quote →
High Pressure Die Casting
Volume, precision, and speed — the industrial production standard
0.05–10kg
Weight Range
±0.05mm
Tolerance
5K–M+
Volume/Year
Ra 0.8
Surface (µm)
Choose HPDC When
Volume exceeds 5,000 pieces per year
Tight dimensional tolerance (±0.05mm) required as-cast
Thin wall (1mm) or complex thin-section geometry
Surface finish Ra 0.8–1.6 µm needed without machining
Get HPDC Quote →
Industry Applications
Where Amsol Aluminium Castings Go
Active OEM supply across 8 industries. Each card shows the component type, the industry, and the aluminium casting process used.
Automotive
Gearbox housings · oil sumps · intake manifolds · wheel hubs · brake calipers
HPDC · LPDC
Pumps & Fluid Systems
Pump housings · impeller bodies · manifold blocks · valve bodies
GDC · LPDC
Electrical
Conduit bodies · junction boxes · motor housings · heat sinks · LED housings
HPDC
Energy — Solar
Mounting brackets · inverter housings · junction boxes · cable management
HPDC · GDC
Aerospace
Structural brackets · instrument housings · covers — non-safety-critical
GDC · LPDC
Marine
Lightweight deck fittings · instrument housings · LM6 marine-grade components
GDC — LM6
Agriculture
Lightweight covers · switch housings · sensor bodies · control housings
HPDC
General Engineering
Machine covers · bearing housings · gearbox end caps · custom OEM components
GDC · HPDC · LPDC
Quality Assurance
What Leaves Amsol Is Verified. Not Assumed.
Every aluminium casting passes through Amsol's in-house inspection before dispatch — six verification steps, all documented.
Spectrometer Verification
Alloy composition confirmed per heat by in-house OES before pouring. A380 is A380 — measured, not assumed.
CMM Dimensional
3D CMM measures all critical features every batch. Report provided with balloon numbers vs drawing.
X-Ray Porosity Check
Radiographic inspection for internal porosity on pressure-critical GDC and LPDC castings — on request.
Surface Roughness
Profilometer measures Ra on machined surfaces. Ra 0.8 µm or better confirmed on precision surfaces.
PPAP Level 3
Full PPAP packages from real CMM data. PSW, PFMEA, Control Plan, Cpk/Ppk — accepted by global OEM teams.
ISO 9001:2015
Annual third-party audit. Documented procedures for every process step. Non-conformance protocol in place.
Get Started
Your Aluminium Component.
Your Aluminium Component.
Our Process.
Share your drawing. An Amsol engineer will recommend GDC, LPDC, or HPDC — with DFM feedback, alloy recommendation, and indicative pricing in 24 hours.
✓ DFM feedback in 24 hours
✓ NDA available before sharing drawings
✓ ISO 9001:2015 certified
✓ 40+ years aluminium casting expertise