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Die Casting
With over 35 years of die casting expertise, Formkon delivers high-quality aluminium and magnesium prototypes and small series. From 50 to 5000 units, we ensure precision, reliability, and fast delivery to meet the highest standards.
Reliable Service & Open Communication
Fast and On-Time Delivery
Up to 3000 Tons Clamping Force
Production in Denmark & Ningbo
Die Casting – High-Quality Prototypes and Small Series Production
For over 35 years, we have been a trusted partner for die cast prototypes and small series production in aluminium and magnesium. Our focus is on delivering complex components quickly and reliably, meeting the highest industry standards.
Comprehensive Die Casting Services
Prototype Production
We specialise in the fast and precise production of prototypes, shortening your development timelines and accelerating your product launch.
Small Series Production
Our efficient small batch production are of the highest quality and ideal for pilot projects and market testing.
Materials and Component Sizes
We work exclusively with aluminium and magnesium, manufacturing components on die casting machines with clamping forces of up to 3000 tons.
Post-Processing Services
To further enhance the quality and functionality of your components, we offer a wide range of post-processing services, tailored to your specific needs.
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Your Project Deserves Excellence
Customised In-House Post-Treatments for Precision and Quality
At Formkon, we provide a complete suite of in-house services, designed to complement and elevate your die casting projects. Our cutting-edge capabilities ensure the highest levels of precision, efficiency, and consistent quality throughout the entire production process.
- Flow Simulations: In-house analysis using advanced flow simulations to optimise material flow, ensuring stronger and more reliable components.
- Friction Stir Welding: Advanced Friction Stir Welding techniques
,providing strong, precise joints for critical applications requiring optimal durability. - Leak Testing: Thorough leak testing to ensure component integrity and prevent failures in critical applications.
- Laser Engraving Durable and detailed marking solutions customised to your needs.
- CNC Machining: Precision CNC machining with 20 high-tech centres, ensuring exceptional accuracy and surface finish for even the most complex components.
- Impregnation Improving durability and sealing components against leaks
- Measurement Reports: Comprehensive measurement reports that provide thorough documentation, ensuring complete quality assurance for every component.
- Technical Cleaning: In-house technical cleaning to remove contaminants, ensuring compliance with the highest industry standards for critical applications.
- Small Assembly Tasks: Efficient small assembly tasks to streamline your production process and added convenience for your project.
- Surface Treatment Enhancing both the appearance and functionality of your components, with options like anodising and coating.
Die Casting Prototypes – The Process Explained
Professional Guidance
Precision CNC Machining
Advanced Casting Simulations
Rigorous Quality Control
Prototype Tools
Fast and Reliable Delivery
Ultimate Precision – CNC Machining for Die-Cast Components in Our Advanced Facility
High-Quality Die Casting Prototypes and Small Series Production
Formkon specialises in precision die casting of aluminium and magnesium prototypes and small series components. With over 35 years of experience, we deliver reliable results tailored to demanding industries.
Die casting outperforms alternatives like CNC machining, 3D printing, and sand casting by producing fully functional prototypes with accurate material properties and an unmatched high-quality post treatments.
Why Choose Aluminium and Magnesium Die Casting for Prototypes and Small Series?
- Exact Alloy Matching: Our die casting solutions ensure compatibility with series-production materials, making them ideal for critical applications like crash-testing.
- Superior Mechanical Properties: Experience reliable functional testing and seamless pre-production runs with our precision-engineered components.
- Exceptional Surface Post treatments: Achieve unparalleled quality and aesthetics with the distinctive die-cast skin.
- Production-Ready Design: Streamline your transition to series production with DFM (Design for Manufacturing) support and advanced casting simulations.
Learn how our advanced die casting solutions can meet your project’s needs – contact us today
Aluminium and Magnesium Die Casting – Our Core Expertise
Expert Guidance and Fast Delivery Are Only the Start – Quality Drives Everything We Do
At Formkon, quality is the foundation of our service. From the first consultation to the final delivery, we ensure every step
reflects our commitment to precision, reliability, and your business success.
Die casting prototypes – examples
FAQ – Your Questions About Die Casting Answered
Formkon specialises in producing prototypes and pre-series in volumes ranging from 50 to 5000 parts. Our team delivers precise and functional solutions tailored to your specific requirements. We also support small-series production when the components and project demands align with our manufacturing capabilities. Contact us to learn more about our production options.
With over 35 years of experience, Formkon combines advanced die casting techniques with expert design support and post-processing capabilities. We deliver customised solutions for prototypes and small-series production, tailored to meet your exact requirements. Learn more about our expertise and values
Die casting offers several advantages, including:
- High precision: Perfect for intricate and detailed components.
- Exceptional surface quality: No need for extensive post treatments.
- Material consistency: Achieve excellent mechanical properties.
- Cost-efficiency: Ideal for prototypes and small-series production without compromising quality.
Die casting combines precision, efficiency, and versatility: making it the ultimate solution for complex projects. Contact us to explore how our die casting expertise can enhance your next project.
To ensure your components meet the highest standards, Formkon offers a range of in-house post-processing services, including:
- Friction Stir Welding
CNC machining - Laser engraving
- Leak testing
- Surface treatment
- Technical cleaning
- Assembly tasks
Formkon typically delivers prototypes within 6 to 15 weeks, depending on complexity and requirements. This includes all necessary post-processing, such as CNC machining and surface treatments.
we also offer investment casting, providing flexibility to meet diverse project needs.
Lightweight metals combine durability with reduced weight, making them ideal for applications that demand strength and efficiency. These materials provide excellent mechanical properties, high resistance to wear, and enhanced thermal performance, ensuring reliable results across a range of industries.
Die casting is essential for industries requiring high-precision components, including:
- Automotive: Lightweight parts for fuel efficiency and electric vehicles.
- E-Mobility: Durable and lightweight components for electric motors and batteries.
- Industrial Automation: Complex parts for machines and systems.
- Electronics: Reliable and high-performance casings and components.
- Defence Industry: Reliable and high-performance components for demanding environments.
- Aerospace Industry: Lightweight and durable parts for aircraft and spacecraft applications.
Yes, Formkon specialises in creating high-quality prototypes and small serie production with die casting. Our in-house capabilities ensure fast turnaround times, precise results, and the flexibility to adapt to your specific project needs.
Getting started is simple. Reach out to our team via our contact form or give us a call. Our secure online form makes it easy to upload and share files safely. We’ll guide you through the design and manufacturing process, ensuring your die casting project is delivered on time and to the highest quality standards.
