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Aluminium Die Casting
Prototypes and Small Series in Aluminium Die Casting
– including all post-treatments
Aluminium Die Casting Prototypes for the Automotive Industry
For over 35 years, we have been supplying the automotive industry with complex, high-precision components using the aluminium die casting process. As experienced specialists, we focus on prototypes, pre-series, and small batches for new development projects – primarily in the automotive sector, but also for other industries.
What we offer
Prototype Production
Reliable and efficient production of aluminum die-cast prototypes, minimising development time and accelerating market entry. Typical delivery time is 6–15 weeks, including all post-processing
Small Series Production
Efficient production of small batches with consistently high quality – ideal for pilot projects and market tests.
Post-Processing
Following casting, we provide a comprehensive range of post-processing options to further optimise the quality and functionality of your components.
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Additional Services for Your Die Casting Projects
- Design Consulting: Refine your casting components for performance and manufacturability.
- CNC Machining: Precision manufacturing using 20 state-of-the-art machining centres for complex geometries.
- Laser Engraving: High-precision laser marking for traceability, branding, and detailed part information.
- Leak Testing: Reliable leak detection processes to verify sealing and structural integrity.
- Friction Stir Welding: Create strong, seamless joints for critical applications.
- Impregnation: Improve porosity resistance and enhance long-term durability under demanding conditions.
- Inspection Reports: Receive detailed documentation for quality assurance.
- Technical Cleaning: Deliver components free of contaminants for optimal performance.
- Small Assembly Tasks: Integrated assembly services to streamline your supply chain and save valuable time.
- Professional Full Simulations: Predict material flow and optimise casting performance with advanced simulation tools.
Machine List – Aluminium Die Casting (Cold Chamber)
| 160 Tons | 500 Tons | 1.600 Tons |
| 180 Tons | 800 Tons | 2.000 Tons |
| 280 Tons | 1.100 Tons | 2.500 Tons |
| 350 Tons | 1.200 Tons | 3.000 Tons |
Simulations – Perfect Preparation for Your Projects
At Formkon, we ensure highly efficient and precise preparation of your die-casting projects. Using our in-house, state-of-the-art simulation software, our experts analyse material flow, filling behaviour and potential weak points already in the planning phase. This end-to-end in-house analysis guarantees consistently high quality and minimises development risks.
Benefits of Our Aluminium Die Casting Simulations
- Want to eliminate development risks? Our die casting simulations in aluminium detect weak spots early—so you know exactly how your part performs before tooling.
- Looking to cut production costs? Precise aluminium casting analysis prevents errors and rework, saving you time and money.
- Perfect Tool Design: Optimize your die casting moulds for maximum productivity, durability and ideal material flow.
Aluminium Die Casting – High-Performance Prototypes
For series-production parts in aluminium die casting, this process is also the ideal choice for prototypes and pre-series. Compared to alternative prototyping methods such as milling, 3D printing, or sand casting, die-cast prototypes provide significant advantages: fully functional components, precise material properties, and the crucial casting surface that enhances durability.
Want to explore the full potential of aluminium die-cast prototypes? Get in touch with us today.
Aluminium Die Casting Prototypes – Examples
Frequently Asked Questions (FAQ)
We deliver parts within 6–15 weeks. This timeframe covers all production stages, including simulation, tool manufacturing, casting, and all post-processing steps and quality control.
Contact us today to learn how our aluminium die casting solutions help drive your project forward with precision and reliability.
We focus on prototypes and pre-series, primarily for the automotive industry. However, we also offer small series production, especially for other industries where production volumes are lower. Typical quantities range from 50 to 5,000 units.
Confidentiality Guaranteed – Your Data Is Safe with Us
We understand how crucial confidentiality is when developing innovative projects. That’s why we are happy to sign a Non-Disclosure Agreement (NDA) to ensure your ideas and data remain fully protected.
