Die Casting Cost Calculator

Mold costs depend on part size, complexity, material, and number of cavities. For small zinc alloy parts (under 100mm), a 1×2 cavity mold typically costs $3,000–$4,000. For larger aluminium parts (150–250mm), single-cavity molds range from $6,000–$12,000. Multi-cavity family molds can be more cost-efficient per part. These are one-time investments, once made, the mold can typically produce 80,000–100,000+ shots before major refurbishment.

Our minimum order is 100 pieces, but 1,000 pieces or more is strongly recommended. At 100 pcs, material procurement is harder, production scheduling is inefficient, and the per-unit manufacturing cost is significantly higher. At 1,000+ pcs, all costs amortize more favourably and lead times shorten. For quantities below 100, CNC machining or sand casting may be more economical.

This calculator provides a directional estimate based on our real factory pricing logic, including material cost (at current Shanghai Metal Market rates), machine rates by tonnage, yield loss, and surface treatment. Actual quotes may vary depending on your specific part geometry, wall thickness, tolerance requirements, and surface finish specifications. For a binding and precise quote, send us your CAD files (STEP/STP/IGS).

Zinc alloy (Zamak) is denser (~6.6 g/cm³ vs aluminium's ~2.7 g/cm³) but has excellent flow properties, allowing thinner walls and finer detail. Zinc die casting uses hot-chamber machines, which have lower cycle times and operating costs. Aluminium requires cold-chamber machines with higher clamping forces. For small precision parts, zinc is often cheaper per piece; for large lightweight structural parts, aluminium wins on material cost. Current raw material pricing (April 2026): Aluminium ~$3.61/kg, Zinc ~$3.43/kg (Shanghai Metal Market).

Per ISO 8062-3:2023, die castings are typically graded CT4-CT9. For aluminium alloy general structural parts (100-300mm), CT6-CT7 is standard, delivering ±0.7-1.0mm linear tolerance. Zinc alloy achieves CT5-CT7 reliably due to superior flow. Precision features requiring tighter tolerances (CT4-CT5) are achievable but require premium tooling and tighter process control. Features requiring very tight tolerance can be post-machined.

Standard mold lead time is 4-6 weeks for simple to medium complexity parts. Complex molds with multiple slides or lifters may take 6-8 weeks. After mold approval, production samples (T1) are provided for customer sign-off before mass production begins. Send us your 3D files (STEP/STP/IGS) for an accurate tooling lead time with your quote.