ForceBeyond provides superior-quality custom die casting parts and components for a wide range of global industries, including automotive, aerospace & defense, energy, medical devices, and oil & gas. Utilizing advanced die casting presses ranging from 180 to 2,000 metric tons, we have the scalable capacity to produce non-ferrous metal parts weighing from a few grams up to more than 100 pounds.
We specialize in high-volume precision casting across multiple materials, including aluminum die casting, zinc die casting (ZAMAK), A356-T6 structural alloys, and magnesium die casting. Our end-to-end manufacturing network combines engineering expertise with high-speed production, delivering monolithic, high-strength parts that are fully machined, coated, and ready for final assembly.
ForceBeyond ensures all die-cast components meet rigorous dimensional and material standards. We offer a diverse portfolio of aluminum and zinc (ZAMAK) alloys to match the precise mechanical, thermal, and finishing requirements of your application.
| Material Grade | Tensile Strength (MPa) | Thermal Cond. (W/mK) | Key Features & Optimal Applications |
|---|---|---|---|
| Aluminum A380 | 325 | 96 | Best balance of mechanical and thermal properties. High resistance to hot cracking. Ideal for engine brackets and gearboxes. |
| Aluminum A360 | 317 | 113 | Excellent pressure tightness and fluidity. High strength in elevated temperatures. |
| Aluminum B390 | 317 | 134 | Exceptional hardness and wear resistance. Ideal for combustion engine pistons and compressor bodies. |
| ZAMAK 2 | 359 | 105 | Excellent damping capacity and vibration attenuation. High strength and hardness after long-term aging. |
| ZAMAK 3 | 283 | 113 | Great balance of physical/mechanical properties. Excellent castability and dimensional stability. Superior plating characteristics. |
| ZAMAK 5 | 328 | 109 | Higher copper content for increased strength. More readily plated, finished, and machined than Zamak 3. |
| ZA 8 | 374 | 115 | Excellent creep properties, strength, and hardness. Ideal for decorative applications requiring premium finishing. |
(Note: We also cast Aluminum 413, 383, A413, A356-T6, and various Magnesium alloys based on project requirements).
A reliable supply of precision non-ferrous castings requires a manufacturing partner with advanced technological capacity and rigorous quality oversight.
Die casting is characterized by forcing molten non-ferrous metal into a highly precise mold cavity under immense pressure. The process relies on custom-engineered, hardened tool steel dies. These dies are machined in at least two sections (a stationary fixed half and a movable syringe half) to allow for the seamless ejection of complex geometries.
Depending on the alloy being cast, ForceBeyond utilizes advanced hot-chamber (for zinc alloys and low-melting-point metals) or cold-chamber (for aluminum alloys and high-melting-point metals) machines. Once the molten metal is injected, it rapidly solidifies, capturing intricate details, movable slides, and internal coring before the die opens and the part is safely ejected.
ForceBeyond provides a seamless transition from raw casting to a finished, assembly-ready component. By integrating our high-volume die casting foundries with advanced secondary processing, we eliminate the dimensional “hand-off” risks typically associated with using multiple vendors.
Our In-House Secondary Operations Include:
Our specialized foundry network supports the world's most demanding sectors with lightweight, corrosion-resistant, and highly complex components:
Hot-chamber machines contain the metal melting pot within the machine itself and are used for alloys with lower melting points, like Zinc (ZAMAK). Cold-chamber machines require the molten metal to be ladled into the machine from a separate furnace and are used for higher-melting-point alloys like Aluminum, preventing damage to the machine's pumping system.
Die casting is significantly faster, produces smoother surface finishes, allows for much thinner walls, and holds tighter dimensional tolerances than sand casting. While tooling costs are higher, the rapid cycle times make die casting far more economical for mid-to-high-volume production.
Zinc alloys, particularly ZAMAK 3 and ZA 8, offer excellent finishing characteristics. They are highly receptive to plating, painting, and chromate treatments, making them ideal for visible or decorative components.
