Pre-Production Die Castings

The primary function of prototype castings is to validate both the design and the production process for the casting.

Low pressure or gravity feed castings using sand, plaster or graphite cavities are effective methods of validating the product design only. It does not provide any information regarding the production process or the true properties of an aluminum high pressure die casting.

Pre-production programs usually require a substantial number of engineering changes throughout the design development process. Most changes can be incorporated in FDC tooling within 3-5 days at a fraction of the original tooling cost.



  • Quick Design Change – Most design changes take only a few days
  • Prototype and low volume castings are produced in steel dies using the high-pressure die cast process
  • Validation of the design and the production process
  • Ability to PPAP and produce low to medium volume production
  • Evaluate design changes before incorporating them into a multi-cavity H-13 die
  • Provide a validated single cavity production tool that can be used for low volume applications or simply standby capacity for emergencies
  • Obtain true die cast properties using the correct alloy and HPDC process


Economic Consideration

Die cast prototype and low volume castings are competitive with sand, plaster and graphite castings at approximately 100-300 pieces depending on geometry and size.

Engineering revisions can quickly be incorporated in P-20 steel dies within several days at a significantly lower cost than most pattern changes and with greater accuracy.

Average tool cost: $25,000 – $45,000

Average cost (cast only) : $45.00 – $90.00


Prototypes and Uses