High Pressure Aluminium Die Casting

Norfran specialises in high pressure aluminium die casting — a versatile and highly efficient manufacturing process that produces complex, precision components at scale. Molten aluminium alloy is injected into hardened steel moulds under high pressure using cold chamber machines, a method suited to aluminium’s higher melting point and one that ensures consistent part quality, tight tolerances, and excellent surface finish across high-volume production runs.
Components can achieve intricate geometries, sharp detail, and smooth or textured surfaces straight from the tool, making aluminium die casting a popular choice across the automotive, aerospace, electronics, and industrial sectors.
If your application calls for a denser, heavier component, our zinc die casting service may be more suitable.

Why Aluminium for die casting?

Aluminium offers a compelling combination of properties that make it one of the most widely specified materials in die casting:

• Lightweight strength — an excellent strength-to-weight ratio, ideal for applications where reducing component mass is a priority
• Corrosion resistance — aluminium naturally forms a protective oxide layer, making it well suited to outdoor or harsh environment applications
• Thermal and electrical conductivity — beneficial for heat sinks, enclosures, and electrical housings
  EMI shielding — aluminium provides effective electromagnetic interference shielding, important in electronics applications
• Recyclability — aluminium is fully recyclable without loss of mechanical properties, supporting sustainability goals

Our Facility

Norfran’s high pressure die casting foundry offers an extensive range of machinery, providing flexibility across varying component shapes, sizes, and production volumes. We have significant experience manufacturing pressure-tight castings, as well as castings with integrated components such as fasteners, pipes, and electrical inserts.
As part of our continuous investment programme, 13 of our die casting cells are fully automated, each equipped with ABB 6-axis robots and 2-axis CNC spraying systems — typically deployed for high-volume, long-running production. A further 4 semi-automated machines handle smaller production runs with the same level of quality control.
In total, our facility houses 17 aluminium cold chamber die casting machines ranging from 180 to 800 tonne. [Please contact us to confirm casting weight range.]
Our CNC machining capabilities complement our die casting operation, allowing us to deliver fully finished components where tighter tolerances or additional features are required post-casting.

The Advantages of High Pressure Aluminium Die Casting

High speed production

Die casting delivers complex shapes to closer tolerances than most other mass production processes. Little or no post-machining is required, and hundreds of thousands of identical castings can be produced before tooling needs replacement.

Dimensional accuracy and stability

Parts produced by die casting are dimensionally stable, durable, and heat resistant, consistently holding close tolerances across long production runs.

Strength-to-weight ratio

Die casting is well suited to thin-wall designs that reduce component weight without sacrificing strength. Multiple features can be incorporated into a single casting, eliminating the need for assembly joints or fasteners — meaning the structural integrity of the part relies on the alloy itself, not a secondary joining process.

Multiple finishing options

Die cast parts can be produced with smooth or textured surfaces and are easily plated or finished with minimal surface preparation required.

Simplified assembly

Die castings can incorporate integral fastening elements such as bosses and studs. Holes can be cored to tap drill sizes, and external threads can be cast directly into the part, reducing downstream assembly time and cost.