Die Casting
High-Pressure Die Casting (HPDC)
High-pressure die casting for thin-wall aluminium and zinc components produced at high volume with excellent surface finish and dimensional repeatability.
Home Capabilities Die Casting HPDC
Overview
High-Pressure Die Casting (HPDC)
In high-pressure die casting, molten metal is injected into hardened steel dies at high pressure and solidifies rapidly, producing near-net-shape parts with thin walls and intricate detail. It is the most productive casting route for medium-to-high volume aluminium and zinc components.
Marcus runs HPDC in-house with integrated tool design, casting, and machining, so customers get one accountable partner from die development through finished, inspected parts.
Capability Die Casting
Delivery Build-to-print, in-house managed
Quality IATF 16949 & ISO 9001
Typical materials
Aluminium ADC12 / A380 Aluminium ADC10 Zinc Zamak 3 / 5
What we offer
HPDC Capabilities
✓ Thin wall sections and complex geometry in a single shot
✓ Net-shape casting with minimal secondary machining
✓ High productivity and short cycle times for volume programs
✓ Excellent as-cast surface finish and dimensional repeatability
✓ Integrated ribs, bosses and mounting features
✓ In-house tooling, casting and CNC under one roof
Typical applications
Components Produced with HPDC
✓ Automotive and EV housings
✓ Motor and gearbox covers
✓ Pump and valve housings
✓ Electronic and electrical enclosures
✓ Heat sinks
✓ Brackets and structural covers
Related processes
Explore Die Casting
Part of our Die Casting capability. Explore the related processes we offer under one accountable partner.
Capacity & specifications
High-Pressure Die Casting (HPDC) Capacity
Machine tonnage, material grades and lead times as quoted in the Marcus capability profile.
60 T to 4200 T
Cold chamber
High-pressure die casting (HPDC)
Low-pressure die casting (LPDC)
Gravity die casting (GDC)
4–6 weeks
Tooling
1 week
FAIR samples
4–6 weeks
Production
Aluminium ADC10 ADC12 AlSi10MnMg A380 A384 A356 AC4B
Aluminium LM series LM2 LM6 LM9 LM13 LM24 LM25
Zinc Zamak 2 Zamak 3 Zamak 5 Zamak 7
Magnesium
Lead
CNC machining Powder coating Wet painting Anodising Plating Heat treatment Bead / shot blasting
IATF 16949:2016 & ISO 9001:2015 Certified quality system, with APQP, PPAP, FMEA and SPC documentation on every programme.
Our own plant
Inside the Marcus Facility
50,000 sq ft, Veerapaandi Village, Coimbatore. Everything
below runs under the Marcus quality system — not a partner's.
Tool room Die casting up to 400 T for aluminium and zinc CNC machining Powder coating
Die casting
17 machines
Hot chamber 40 T / 90 T
Cold chamber 138 T / 188 T / 400 T
Materials Zinc, aluminium and lead
CNC machining
20 machines
CNC turning centres
CNC turn-mill centre
CNC vertical milling centres (4-axis support)
CNC drill-tap centre
Surface finishing
Powder coating and painting
Shot blasting
Vibro polishing
Chromation
Resin impregnation
Heat treatment
Inspection
CMM
Optical emission spectrometer
DFT
K-mold tester
Receiving gauges
Gloss meter
Air plug gauges
Leak testing equipment
