Hallam Castings delivers precision aluminium and zinc diecasting solutions for components requiring dimensional accuracy, repeatability and reliable mechanical performance. Our controlled diecasting processes support complex geometries, thin wall sections, fine surface detail and consistent high-volume production, while reducing the need for secondary machining. Material selection is matched to each application, considering strength, weight, corrosion resistance, thermal performance and finish requirements.
Explore our aluminium and zinc capabilities below to identify the most suitable alloy and process for your specific component requirements.
Contact UsHigh Pressure Diecasting (HPDC)
Ideal for high-volume production, HPDC uses steel dies and hydraulic pressure to inject molten aluminium. It delivers excellent dimensional accuracy and surface finish.
Advantages: Fast cycle times, thin walls, high precision.
Best for: Higher volume, dimensional accuracy, repeatability, surface finish.
Sand Casting
A traditional method using sand moulds, perfect for low-volume or large parts. It’s cost-effective and flexible for design changes.
Advantages: Low tooling cost, large part capability.
Best for: Thicker wall-section parts that can be machined afterwards. Prototyping due to low pattern cost.
Gravity Diecasting
Molten aluminium is poured into permanent metal moulds under gravity. It offers better accuracy than sand casting and is suitable for medium volumes.
Advantages: Reusable moulds, good surface finish.
Best for: Medium volumes, thicker wall sections.
Lost Wax Casting (Investment Casting)
This precision method uses wax patterns and ceramic moulds to create highly detailed parts. It’s ideal for low-volume, high-complexity applications.
Advantages: Exceptional detail, smooth finish.
Best for: Prototyping, intricate components that high pressure and gravity can’t achieve.
The difference between pressure casting and sand casting is that pressure casting uses a complex, steel mould to shape the metal, while sand casting uses negative imprint in sand to create a void in the shape of your product, aluminium is then poured in and flows under gravity to fill the empty space.
We strategically design our moulds with well-planned vents and use dynamic CAD models to simulate metal flow, ensuring efficient air displacement during the die casting process.
Our aluminium die casting machines and advanced process capabilities make it possible to produce in high volume with high efficiency, which makes us a key supplier of aluminium castings in the UK. All our manufacturing and administrative operations further meet quality control, safety, sustainability, and process improvement goals by applying Lean Six Sigma methodologies. This position puts the company in a leadership spot in the UK aluminium die casting industry.
We don’t just promise precision; we prove it. Our quality assurance process is built around industry-recognised standards and tools, including:
PPAP Level 1-5 (Production Part Approval Process)
Ensures all customer engineering design and specification requirements are properly understood and consistently met before production begins.
Cpk & Ppk Analysis
We use statistical process control to monitor and improve process capability, ensuring your parts are produced within specification limits with minimal variation.
Poka-Yoke (Error-Proofing)
Built-in safeguards throughout our processes help prevent human error and ensure right-first-time manufacturing.
In-Process and Final Inspections
Every part undergoes detailed inspections using calibrated equipment such as our CNC CMM, with full traceability and documentation available on request.These tools allow us to not only meet your specifications—but to prove it with data.
Aluminium is a great choice for its green credentials, as it’s one of the most recycled elements on Earth. If your part sales have outgrown your current manufacturing process, or legislation has required a material change for safety, environmental, or sustainability reasons, high-pressure aluminium casting could be right for you.
High-pressure aluminium die casting enables the volume production of components with narrow tolerances and excellent surface finishes. This process offers numerous benefits for manufacturers, including the ability to produce intricate shapes quickly and cost-effectively.
Contact UsZinc diecasting is a high-speed manufacturing process suited to complex, high-volume components requiring close tolerances, thin walls and consistent surface finish. Using ZL3 and ZL5 alloys, Hallam Castings produces dimensionally stable parts with strong mechanical properties, good corrosion resistance and minimal secondary machining across a wide range of industrial applications.
Superior Dimensional Stability: Maintains excellent dimensional precision in the as-cast condition, making it ideal for applications requiring tight tolerances
Excellent Castability: Flows smoothly into complex geometries and intricate details with minimal casting defects
Cost-Effective Solution: Optimal balance of performance and economy for high-volume production runs
Consistent Quality: Reliable mechanical properties ensure predictable performance across production batches
Non-sparking materials, making ZL3 and ZL5 an essential choice for applications in potentially explosive environments.
Corrosion Resistance: Good general corrosion resistance, but consider protective coatings for harsh environments.
Improved Surface Finish: ZL5 in Particular has excellent surface preparation characteristics, particularly beneficial for electroplating applications.
ZL3 and ZL5 are established zinc alloys used for hot-chamber pressure die casting and conform to EN 1774 specifications. ZL3 provides good dimensional stability, castability and surface finish, making it suitable for general engineering components. ZL5 contains additional copper, providing greater tensile strength, hardness and creep resistance where higher mechanical performance is required.
Both alloys can produce complex, thin-walled components to close tolerances and offer non-sparking properties for safety-critical environments. Our technical team can advise on the correct alloy for your component and operating conditions.
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Yes, ZL3 and ZL5 can achieve tighter tolerances than aluminium or magnesium diecasting, with typical tolerances of ±0.1mm and excellent repeatability across production runs.
Zinc diecastings can be finished with a variety of options, including electroplating, powder coating and painting. Electroplating with materials like copper, nickel, or chromium is common for decorative purposes and corrosion resistance.
Depending on the parts mass properties, generally speaking, cycle times for Zinc castings are faster than those of Aluminium and Magnesium castings. This is due to thinner wall sections that are achievable and the lower casting temperature of the molten metal, combined with thin casting wall sections.
Zinc generally provides better mechanical properties, including higher strength and rigidity, compared to aluminium and magnesium. It also allows for thinner walls and more intricate details. Zinc also has excellent machinability regarding milling, turning and especially tapping threads.
Technical Specifications
ZL3
ZL5
