Views: 0 Author: Site Editor Publish Time: 2025-05-06 Origin: Site
Low Pressure Die Casting (LPDC) is a manufacturing process used to produce high-quality metal parts by forcing molten metal into a mold cavity under controlled, low-pressure conditions. This process is especially common in the automotive industry, where strength, consistency, and lightweight performance matter.
Unlike gravity casting where metal flows freely, LPDC controls the fill speed and direction, reducing turbulence. This results in dense, accurate components with fewer defects. At the core of this process is the LPDC mold, which is engineered to withstand thermal stress while delivering high-precision geometry.
Wondering why LPDC is so popular in modern manufacturing?
Here are the top benefits of using the low pressure die casting process:
Improved Surface Finish – Excellent for components that require minimal post-machining.
Greater Dimensional Accuracy – Reduces the need for machining.
Low Porosity – High integrity with minimal gas or shrinkage defects.
Good for Thin Walls – Thanks to controlled filling, wall thicknesses as low as 3 mm can be achieved.
Material Efficiency – Reduced waste and recyclable excess metal.
These advantages make LPDC ideal for applications that demand both structural strength and tight tolerances—especially in automotive parts such as alloy wheels, battery enclosures, and suspension elements.
The low pressure die casting diagram helps visualize the steps clearly:
Furnace Setup: Molten aluminum is kept at a constant temperature.
Pressurization: Gas pressure pushes the molten metal up through a riser tube.
Cavity Fill: The metal enters the LPDC mold from the bottom upward.
Solidification: Controlled cooling allows metal to harden evenly.
Part Ejection: After the pressure is released, the part is removed from the mold.
This process is repeatable and suitable for producing thousands of identical components.
LPDC molds are heavily used in:
Electric vehicles (EVs) – for battery packs and structural enclosures.
Automotive – for aluminum alloy wheels and suspension systems.
Aerospace – where strength-to-weight ratio is critical.
Motorcycles – brake components and engine mounts.
Lighting and consumer electronics – for aluminum housings.
LPDC typically uses non-ferrous alloys. The most common are:
Aluminum Alloys (A356, A360, A380) – Ideal for structural performance.
Magnesium Alloys (AZ91D) – Used when weight savings are crucial.
Copper-Based Alloys – For industrial components.
Material selection can influence minimum achievable wall thickness and final mechanical properties.
One of the highlights of LPDC is its finish quality. Due to reduced turbulence during filling, parts often need minimal post-processing. Common surface treatments include:
Sand blasting or shot blasting
Machining for tight-fit areas
Anodizing or powder coating
The smoother the initial cast, the more cost savings downstream.
The industry standard for minimum wall thickness in LPDC generally ranges between 3 mm to 4 mm. However, this varies based on:
| Factor | Effect on Wall Thickness |
|---|---|
| Alloy Fluidity | High fluidity enables thinner walls |
| Casting Size & Shape | Larger parts require thicker walls for strength |
| Cooling Strategy | Fast, uniform cooling allows thinner cross-sections |
| LPDC Mold Design Quality | Precision molds like those from Superband ensure better consistency |
With advanced tooling, mold simulation, and automation—as used at Superband—even thinner sections may be viable.
Here’s why choosing an LPDC mold can benefit your operations:
✔️ Customization Flexibility: Complex geometry, multi-cavity options, optimized cooling.
✔️ Extended Mold Life: LPDC puts less thermal shock on molds compared to HPDC.
✔️ Efficient for Medium-Volume Runs: Cost-effective for high-integrity production runs.
Superband’s LPDC molds are widely used in:
Lightweight EV structural parts
Aerospace-grade alloy wheels
High-strength automotive parts in suspension systems
Every process has trade-offs. Here's a quick comparison:
| Feature | LPDC Advantages | LPDC Drawbacks |
|---|---|---|
| Wall Thickness | 3–4 mm achievable | Not as thin as HPDC |
| Surface Quality | Excellent | Requires mold precision |
| Tooling Cost | Higher upfront | Lower long-term due to longevity |
| Cycle Time | Slower than HPDC | Better quality over speed |
| Defect Rate | Lower porosity | Requires skilled setup |
In summary, LPDC molds prioritize quality, strength, and consistency over production speed.
Let’s compare low pressure vs high pressure die casting for your project:
| Feature | LPDC | HPDC |
|---|---|---|
| Pressure | 0.1–1 MPa | 100–200 MPa |
| Porosity | Very Low | Higher without vacuum assistance |
| Cycle Time | Moderate | Very Fast |
| Wall Thickness | 3–4 mm (standard) | Can go below 2 mm |
| Application | Wheels, frames, e-mobility parts | Housings, electronics, fast-cycle |
If your product demands high-strength parts with moderate complexity and low porosity, LPDC molds are the clear winner.
LPDC may not be suitable if:
You need ultra-high speed production (e.g., mass-market electronic enclosures).
Your material is ferrous (iron-based metals are not suited for LPDC).
The part geometry requires wall thickness below 2 mm consistently.
In these cases, you may want to explore high-pressure die casting, sand casting, or investment casting.
Established in 1990, Foshan Nanhai Superband Mould Co., Ltd. is a global leader in mold design and aluminum casting solutions. They produce over 3,000 sets of molds annually, supported by:
500+ advanced CNC and robotic systems
17 die casting lines from 350T to 3050T
Full in-house engineering and trial-run systems
Certified quality systems: ISO 9001, IATF 16949, VDA 6.4
Superband’s LPDC offerings span multiple industries including EV, motorcycle, aerospace, and more.
Low pressure die casting molds are critical in:
Electric vehicles: Battery covers, subframes, inverter housings.
Passenger cars: Aluminum wheels, steering knuckles.
Motorcycles: Suspension arms, brake calipers.
Lighting: Heat sinks, housings for high-power LEDs.
Precision machinery: Enclosures requiring strength and accuracy.
If you're aiming for precision, structural performance, and durability—especially in aluminum or magnesium parts—then LPDC molds are the ideal investment. They offer a perfect mix of reliability, customization, and long-term cost-effectiveness.
By partnering with experienced suppliers like Superband, you gain access to world-class tools, simulation support, and process optimization for superior casting outcomes.
Q1: What is the minimum wall thickness possible with LPDC molds?
A1: Typically 3–4 mm, but advanced design and materials can allow slightly thinner walls in specific cases.
Q2: Is LPDC suitable for electric vehicle manufacturing?
A2: Absolutely. It’s widely used for EV components like battery casings, motor mounts, and lightweight structural parts.
Q3: What affects the wall thickness in low pressure die casting?
A3: Key factors include alloy type, mold design, cooling strategy, and the complexity of the casting.
Q4: Are LPDC molds more expensive than HPDC molds?
A4: They have higher upfront costs but offer longer lifespan, less defect scrap, and better consistency, making them cost-effective over time.
Need a trusted partner for your next LPDC project? Superband offers full-solution design, manufacturing, and support services to bring your idea to life—whether it’s a next-gen electric vehicle or high-performance aluminum component.
