Die Casting Tolerances: The Ultimate FAQ Guide

Die casting tolerances refers to various deviations from the required measurements or dimensions or die cast parts.

They are values within which a part is acceptable for use.

Die casting tolerances vary depending on the metal alloy, size or die casting process.

So, if you want to learn more, read this guide.

What Are The Benefits Of Die Casting Tolerance?

Die cast zinc parts

Die cast zinc parts

The main benefits of using die casting tolerance during fabrication process include:

Enhances Durability

Die casting tolerance ensures you have the right dimensions for your machine part. The right dimension is integral in ensuring the application serves the intended purpose thereby ensuring its durability.

High Quality Production

The different tolerance procedures produce high quality products which passes all the specification standards.

These processes allow you to detect part which do not meet the required standards and remove them.

For instance, defects arising from non-uniformity cooling do not reach the final production stage. This results in high quality machine parts for your use.

Low Operating Cost

High quality and durable machine parts is essential in the proper functioning of your application. You therefore have a machine that does not easily breakdown or require maintenance often.

The effect of this is it reduces the overall operating cost of your application.

What Is Die Casting Tolerance Limit?

Die casting tolerance limit refers to a limiting value that determines the acceptable measurement of a part.

You can have two die casting tolerance limit, linear and geometric tolerance limit.

The value determines how well you can die cast your metal.

What Are The Types Of Die Casting Tolerance?

Die casting tolerance is available in two types, that is, conventional die casting and multi-slide die casting tolerance.

The choice of which one to use depend on different factors like type of application and the metal alloy in use.

What Is The Difference Between Conventional And Multi-slide Die Casting Tolerance?

Th main difference between a conventional die casting tolerance and a multi-slide die casting tolerance is the number of tools in use.

A conventional die casting tolerance uses a two-part tool when fabricating tolerance.

A multi-slide die casting tolerance requires more than two tools for accurate tolerance effect.

Multi-slide die casting tolerance is relatively expensive compared to conventional die casting tolerance.

The usage of multi-slide die casting tolerance is common due to the benefits if offers to the different machine parts.

Where Can You Apply Die Casting Tolerance?

Die casting tolerance is critical in all die casting process applications.

It does not matter whether you’re making parts in the automotive, medical, aerospace, or metal fabrication industry.

Remember, die cast parts with tighter tolerances, tend to be more expensive.

Of course, it requires you to control a range of die casting parameters.

Die cast part with tight tolerance

Die cast part with tight tolerance

What Is The Effect Of Not Achieving Die Casting Tolerance?

Not achieving the right die casting tolerance can have negative effects on your metallic products. Such problems include:

Improper Functioning Of Your Machine

There is a likelihood of your machine not functioning properly if you don’t achieve the right die casting tolerance.

For instance, the metallic part of your machine can easily wear off or break due to lack of proper metal strength.

Die casting tolerance has the effect of hardening your metallic parts which facilitates the proper functioning of your machine.

Extra Machining Required

You have to further work on your metallic parts if you want a strong and durable machine part. The effect of this is it increases the overall working process for your metal.

This has an impact on the final pricing of your machine.

Is There A Difference Between Die Casting Tolerance and Sand Casting Tolerance?


There is a difference between die casting tolerance and sand-casting tolerance.

The main material for fabrication in die casting is a metallic mold. Sand casting tolerance depends on a pile of sand for production of the final product.

Sand casting tolerance is the common type of since it is relatively available and cheaper than die casting tolerance.

Which Equipment Can You Use To Control Die Casting Tolerance?

You need to use the following tools when performing a die casting tolerance:

Steel Rule Dies

Steel rule die is a vita tool that you need especially when you are working on metallic parts which do not require tight tolerance.

It is vital that you select the ejection rubber carefully when using this tool to enhance the accuracy of your design.

Solid Milled Dies

The function of a solid milled die is to assist you achieve the metal part tolerance that you need for your machine.

It is a vital tool when you want to achieve consistency, reliability and repeatability outcome for your metallic parts.

The advantage of this tool is there is minimal flexing and distortion while cutting the die. Using this tool is costly though you have a guarantee of getting value for your money.

Rotary Dies

The use of a rotary die is vital when you are working on thin materials whose films is less than 0.062’’. you can control the depth of a rotary die when you want to achieve kiss cutting.

Matched Metal Dies

Matched metal dies are available as both make and final metal dies. They are relatively expensive than the other type of tools.

A matched metal die is critical in application that you need high tolerance.

What Affects Wall Thickness In Die Casting Tolerance?

The following factors have an impact on the wall thickness of your metal during die casting tolerance:

Size Of The Metal Part

Understanding the size of your metal part helps in determining the wall thickness during die casting tolerance. The thickness of your metallic part should corespond to its size for proper functioning.

Usage Of The Metal Part

Where you want to apply the metal part should determine the thickness of the metal. For instance, if you are installing the metal part on a heavy machine, then you nee to make it thicker.

This helps in the proper functioning of the machine and prevents a breakdown of the metal part.

Alloy Type

The availability of different types of alloys gives you an opportunity to select the one you want for the die casting tolerance process.

Each of these metals have an effect on the level of thickness they can get.

It is important to consider the type of alloy you are using and the application.

This helps in getting the right alloy for the correct thickness that you can install on your application.

What Are The Effects Of Non-Uniform Cooling During Die Casting Tolerance?

Non-uniform cooling of your metal during die casting tolerance has a negative effect on its function.

This is due to the various problems that arises during the process.

Some of these problems include:


Bubbles is the major defect that arises from non-uniform cooling of your metal part during the die casting process. this has an impact on the durability of your metal part.

This is because it tends to be weak in these areas. A metal part that has bubbles is not ideal for machining since it negatively affect the performance of your application.

Ejector Masks

Your metal part experiences ejector masks when they eject under high force. It can also be as a result of you subjecting to less cooling duration.

Ejector masks reduces the quality of your metal part and its visual appeal.

Hot Tearing

Hot tearing is what happens when you subject your metal part to different cooling temperatures. The effect of this is you will have cracks on your metal part which affects its quality since it is easy to break.

Unfilled Section

Unfilled section means your metallic part does not have uniform thickness. This affects the die casting effects since you cannot achieve a uniform thickness layer.

The effect of using a metallic part with unfilled section is you end up with a poor-quality part.

What Is A Die Casting Tolerance Chart?

This refers to a chart that indicates the tolerance limit for various metals and alloys. It helps in determining which metal to use in the fabrication of a given machine part.

What Is Die Clearance In Die Casting Tolerance?

Die clearance refers to the available space between the pie and punch. This happens when you insert the punch through the die opening.

What Are The Specifications For NADCA?

NADCA covers the following specifications on your die casting tolerance:

Dimensional Tolerance

There are various dimensional tolerances that you have to consider. They include length, height and thickness of your metal.

Angular Tolerance

Angular tolerance consists of several aspects which you have to consider during die casting tolerance. They include parallelism, flatness and perpendicularity tolerance.

Flatness Tolerance

Flatness tolerance outlines the flatness procedure that you can applly on your metal part. Flat tolerance helps in determining the area of application you are going to use the machine part.

What Is Shrinkage Allowance In Die Casting Tolerance?

High performance die cast part

High performance die cast part

Shrinkage allowance in die casting helps in the specification of length difference of the cast parts between casting and casting mold.

It is either an external or an internal change in volume of a metal.

This takes place when a particular metal transitions from a solid to liquid state. You can ascertain shrinkage allowance during non-destructive test.

Shrinkage allowance usually takes place in three phases.

That is, solid, solidification and liquid.

For all your questions or inquiry about die casting tolerance, contact us now.

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