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Dimensional Accuracy for Series Quality

Tolerances in Die Casting

In industrial applications, precise tolerances are a crucial factor for the fit and functional reliability of components. When optimally controlled, the die casting process allows for high dimensional accuracy – especially in large-scale production under consistent conditions.

What Tolerances Are Realistic in Die Casting?

Achievable tolerances in die casting depend on several factors, including:

  • Component geometry
  • Material (e.g., aluminum, zinc, magnesium)
  • Complexity of the mold
  • Tooling quality
  • Process control & temperature regulation

Die casters typically refer to DIN EN ISO 8062-3, which defines general tolerance classes for castings. In zinc die casting, tolerances of ±0.03 mm are possible for small parts, while aluminum die casting commonly achieves ±0.1 mm - depending on wall thickness and part size.

Overview of Tolerance Classes

Tolerance Range        Typical Material                 Example Deviation
Fine (e.g., CT 5-6)             Zinc                         ±0.03 - 0.05 mm
Medium (e.g., CT 6-7)    Aluminum              ±0.05 - 0.1 mm
Coarse (e.g., CT 8+)          Magnesium, large parts        ±0.1 - 0.2 mm

Note: The exact tolerance must always be evaluated on a case-by-case basis.

Why Tolerances in Die Casting Matter

  • Component Fit: Tolerances determine how well die-cast parts integrate with other components.
  • Functionality: Excessive deviations may lead to play, friction, or leakage.
  • Cost Optimization: Precise production reduces rework and scrap.
  • Process Reliability: Consistent results enhance production stability - especially in automated manufacturing lines.

Consulting for Die-Cast Parts with Precise Tolerances

Do you need exact information on achievable tolerances for your component? We’re happy to evaluate which accuracies are technically and economically feasible with our production partners in China.

Get in touch now - we’ll advise you personally.

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