Die Casters
In die casting fluid is injected into a mold at high pressures. Set-up time for dies is 1-2 months, after which production rates of 20–200 pieces per hour-mold are normally obtained. Maximum mass limits for magnesium, zinc, and aluminium parts are roughly 4.5 kg, 18 kg, and 45 kg, respectively; the lower limit in all cases is about 30 g. Die injection machines are generally large (up to 3 × 8 m) and operate at high pressures — 100 megapascals (1000 kgf/cm2) and higher, although aluminium usually is processed at lower pressure. A well-designed unit produces over 500,000 castings during the production lifetime of a single mold. The major production step is die construction, usually a steel alloy requiring a great deal of skill and fine tooling to prepare. Only non-ferrous materials are die cast, such as aluminium, zinc, magnesium, and copper-based alloys.
This is the process used in the production of certain toys, notably that of model automobiles, see: die-cast toy, Matchbox
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