Gravity Die Casting

Gravity Die Casting | Reliable Aluminium & Copper Castings

Gravity die casting (GDC) uses the natural force of gravity to fill reusable steel dies with molten aluminium or copper alloys — delivering dense, consistent castings at lower tooling investment than pressure processes. Ideal for mid-volume production of thick-section, structurally sound components across marine, lighting, defence, and industrial applications. Partner with Marcus Hi-Tech for castings that combine process economy with proven structural integrity.

How It Works

Step 1: Design Review

Our engineers assess wall thickness, fill path, and solidification direction. Tilt casting is recommended where turbulence-free fill is critical for deep or narrow sections.

Step 2: Alloy Selection

We select from LM6 (marine), LM25-T6 (structural), LM4 (general engineering), or Aluminium Bronze (seawater service) based on your performance and environment requirements.

Step 3: Mould Build & First-Off

Reusable steel or cast iron moulds are fabricated and die-coated. First-off samples are inspected for dimensions, fill quality, and surface finish before production approval.

Step 4: Production & Despatch

Full batch records, material certificates, and inspection reports accompany every shipment. Post-cast operations — fettling, shot blast, CNC machining, surface treatment — handled in-house.

Product

1. Marine Outboard Engine Bracket

Model ID: MHT-MAR-EBK-LM6

Industry: Marine & Offshore

Description: Saltwater-rated structural bracket for outboard engine mounting. LM6 alloy delivers natural seawater corrosion resistance without coating dependency. Heavy-section walls handle continuous propulsion loads over long service life.

Technical Specifications:

• Material: Aluminium LM6 (Al-Si12)
• Wall Thickness: 6mm – 18mm
• Finish: Shot Blast + Clear Anodize
• Availability: MOQ 200 units

2. LED Street Lighting Housing

Model ID: MHT-LGT-HSG-LM25

Industry: Lighting & Infrastructure

Description: Weatherproof luminaire housing with integral cast cooling fins for LED street and architectural lighting. LM25 ensures dimensional stability for 25-year infrastructure service life. IP66-compatible geometry cast directly — no secondary fabrication.

Technical Specifications:

• Material: Aluminium LM25
• Finish: Polyester Powder Coat (RAL custom)
• Feature: Integral Cast Cooling Fins
• Availability: MOQ 500 units

3. Defence Control Panel Housing

Model ID: MHT-DEF-CPH-LM25T6

Industry: Defence & Security

Description: Ruggedised enclosure for field communications and vehicle-mounted defence electronics. LM25-T6 provides shock and vibration resistance to MIL-STD-810 compatible design levels. Cast-in EMI shielding insert provisions eliminate secondary assembly.

Technical Specifications:

• Material: Aluminium LM25-T6
• Finish: Hard Anodize + Chemical Film
• Feature: Cast-in EMI Shield Provision
• Availability: Low-Mid Volume / Controlled Supply

4. Premium Cookware Body

Model ID: MHT-CKW-PAN-LM6

Industry: Consumer & Household

Description: Thick-base frying pan and casserole body for premium cookware brands. Uniform 5–8mm base thickness ensures even heat distribution across gas, induction, and ceramic hobs. Smooth as-cast surface accepts PTFE and ceramic non-stick coatings with excellent adhesion.

Technical Specifications:

• Material: Aluminium LM6 / Food-Grade Alloy
• Base Thickness: 5mm – 8mm uniform
• Coating: PTFE / Ceramic Non-Stick compatible
• Availability: MOQ 1,000 units

5. Seawater Valve Body

Model ID: MHT-VLV-SEA-ABZ

Industry: Oil, Gas & Marine

Description: Heavy-duty valve body for offshore platform pipework and naval sea chest installations. Aluminium Bronze CA104 resists cavitation erosion, biofouling, and dealuminification in high-velocity seawater — outlasting stainless steel on lifecycle cost. CNC-finished bore to PN16/PN25 pressure class tolerances.

Technical Specifications:

• Material: Aluminium Bronze CA104
• Pressure Class: PN16 / PN25
• Finish: As-cast + CNC Bore Finishing
• Availability: Custom Orders

Testimonial

"LM6 marine brackets — three seasons, zero corrosion. Marcus understood marine alloy selection immediately." —

Capt. Rajan Pillai

Fleet Engineering Manager, Coastal Marine Services

"Consistent fin geometry, perfect powder coat adhesion — we've standardised on Marcus for all our street lighting housings." —

Anand Krishnan

Product Director, Urban Lighting Solutions

"Full material certs and inspection reports with every defence consignment. Always on time, zero NCRs." —

Wg. Cdr. (Retd.) Ashok Menon

Procurement Head, Defence Electronics

"PTFE coating rejections dropped to near zero after switching to Marcus gravity castings. Base thickness consistency is exceptional." —

Elena Marchetti

Quality Director, Premium Cookware Brand, Italy

"CA104 valve bodies have outlasted every stainless alternative on our offshore platform. Cavitation is simply not an issue." —

Gareth Owen

Mechanical Integrity Engineer, Offshore Platform Operator

Frequently Asked Questions

What is gravity die casting?

Molten metal is poured into a reusable steel die using gravity — no applied pressure. It delivers better surface quality and dimensional consistency than sand casting, at lower tooling cost than pressure die casting.

What alloys can be gravity die cast?

LM6, LM25, LM4 aluminium alloys and Aluminium Bronze CA104. Alloy choice depends on service environment, mechanical property targets, and surface treatment.

What volumes suit GDC?

500 to 50,000 parts annually. Below this, sand casting is more economical. Above this, HPDC or LPDC offers better cycle efficiency.

Can GDC castings be heat treated?

Yes. LM25 and LM6 respond well to T6 ageing, significantly increasing yield strength — unlike high-pressure castings which risk blistering during heat treatment.

How does GDC compare to sand casting?

Better surface finish (Ra 3–6 µm vs Ra 12–25 µm), tighter tolerances, and more consistent wall thickness — with lower per-part cost at volumes above 300–500 parts/year.

Where are Marcus Hi-Tech's GDC facilities?

India (Coimbatore, Pune, Bangalore, Chennai, Rajkot), Vietnam (Ho Chi Minh City), and China (Tianjin, Ningbo, Qingdao).