capabilities
Gravity Die Casting
Permanent mould casting for aluminium components, from small end caps to lawn mower decks and light fittings. Cast, machined and finished at our Eagle Farm foundry.
Why gravity die casting
Excellent surface finish. Components come out of the mould smooth and consistent, which reduces finishing work on visible surfaces.
High dimensional accuracy. Permanent metal moulds hold consistent dimensions across a run and keep variation between parts low.
Suitable for heat treatment. Gravity cast parts can be heat treated to improve hardness and strengthen the component.
Greater mechanical properties. Controlled filling minimises trapped air and gas, producing a denser component that performs better under load and over time.
Handles complex shapes across a wide size range. From small precision parts to large industrial castings.
Built for medium to high volumes. Permanent moulds support ongoing production with repeatable quality across large quantities.
What gravity die casting is
Molten aluminium is poured into a reusable steel mould and fills the cavity under its own weight. No pressure is applied, so the metal enters the mould in a controlled, predictable flow, which means one point of accountability from design to finished part.
That control is what separates the process from the alternatives. Filling slowly traps less air and gas than pressure injection, which produces a denser casting with better mechanical properties and one that can be heat treated. The permanent mould gives a better surface finish and tighter repeatability than sand, and it holds those tolerances across a production run.
The trade is tooling. A permanent mould costs more than a sand pattern and takes longer to produce, so the process earns its place at medium to high volumes where that cost spreads across enough parts.
Casting capability
| Capability | Specification |
|---|---|
| Wall thickness | 2.5 to 3mm on small parts, up to 6mm for reliable fill |
| Linear tolerance | ±0.5 to 1.5mm |
| Draft angle | 1 to 2° internal, 2 to 3° external |
| Internal radius | 2 to 4mm minimum |
| External radius | 3 to 6mm recommended |
| Primary alloys | EA401, DA401, CA401 |
| Heat treatment | Available |
Figures are typical and indicative. Final specifications are confirmed at quotation and vary with part geometry, alloy and volume.
Machine capacity
Four casting configurations, selected to suit part size and volume.
| Machine | Maximum casting size |
|---|---|
| Hand die table | 225 × 100 × 25mm |
| Horizontal machines | 500 × 500 × 300mm |
| Tilt machine | 800 × 600 × 400mm, width to 820mm |
| Vertical machine | 450 × 450 × 200mm |
How we cast
Two pouring methods, chosen on part geometry and volume.
Automatic pouring
- Molten aluminium is held in a furnace at the required temperature
- Metal is removed from the furnace manually or automatically
- Metal is poured into a pouring cup, then the machine tilts and the metal flows into the mould cavity
- The cavity forms the raw casting to the customer’s design
- Metal remains in the mould approximately 90 seconds to cool and solidify
- The mould opens and the casting is automatically ejected
- Castings are stacked and prepared for CNC machining or other finishing
Manual pouring
- Molten aluminium is held in a furnace at the required temperature
- Metal is ladled from the furnace by hand
- Metal is poured directly into the mould runner system
- The casting cools and solidifies in the mould for around 90 seconds
- The mould is opened and the casting ejected or removed manually
- Castings are stacked and moved to CNC machining or finishing
What we machine and finish
Castings move straight into our CNC department for drilling, tapping, milling, profiling and surface finishing to ±0.1mm typical tolerance. Design, casting and machining all happen at Eagle Farm, which means one point of accountability.
Alloys
Gravity die casting runs on three primary alloys, EA401, DA401 and CA401.
Other alloys and custom blends can be assessed through our ingot operation.
Typical applications
End caps, lawn mower decks, light fittings.
Components supplied into automotive, mining, agriculture, industrial equipment, electrical housings, infrastructure, OEM manufacturing, and marine wholesale and hardware.
Frequently asked questions
Can you produce a single prototype?
Yes. We produce single prototypes through to large volume production runs, with no fixed maximum.
Can gravity castings be heat treated?
Yes. Gravity cast parts can undergo heat treatment to improve hardness and strengthen the component.
What information do you need to quote?
Drawings, contact details and project requirements to start. We will clarify alloy selection, quantities and any special considerations. CAD drawings are only required once you have engaged with one of our specialists.
Who owns the tooling?
You do. You pay for the tool and the material, so the tool is yours. The tool is yours and we will release it on request.
Do you deliver outside Queensland?
Yes. We quote ex-factory and deliver Australia-wide, using our preferred transport partner or your nominated freight provider.
Have a part to cast?
Send us a drawing and we will assess it for manufacturability.