Aluminum Die Casting

Your trusted partner for high-quality aluminium die casting – with cross-industry expertise!

With our extensive know-how in premium aluminium die casting, we deliver durable, cost-effective components with outstanding precision for a wide range of industries. Aluminium die casting expands our service portfolio with a process ideally suited for lightweight and structurally resilient parts. Whether as a housing component, structural element, or technical surface – HDO is your go-to manufacturer for aluminium die-cast parts across diverse applications. Our expertise is based not only on state-of-the-art technology, but also on decades of development experience and the ability to translate complex requirements into smart, cast-part solutions.

Aluminium die-cast parts by HDO – custom made, lightweight, and durable

At HDO, we’ve long set the standard in the production of aluminium die-cast components. Thanks to high-performance casting systems, advanced machinery, automated production lines, and digitally supported quality management, we ensure consistent, top-quality manufacturing with maximum process reliability.
Aluminium die casting is ideal for components that combine low weight with high strength, excellent corrosion resistance, and outstanding thermal conductivity. Whether used as heat sinks, device housings, or functional modules, our aluminium parts impress with dimensional stability, sealing performance, easy post-processing, and an excellent strength-to-weight ratio.
But we don’t stop at production: in close collaboration with our clients, we optimise design, castability, and functionality to develop customised, cost-effective, and reliable series-production solutions that meet the growing demands of modern industry.

HDO – custom aluminium die casting

At HDO, aluminium part production starts well before the casting process. It’s the result of intensive development, precise process control, and tailored implementation. We manufacture custom aluminium components for applications including:

Equipment and machinery housings for industrial manufacturing
Design and functional elements for automotive interiors, such as shift paddles
Technical components for automotive and mobility applications, like heat sinks and display housings
Components for electrical, energy, and building technology, such as thermostat sleeves

Our cast parts offer high sealing performance, excellent thermal conductivity, outstanding machinability, and exceptional corrosion resistance. They are easy to mill, drill, or coat – ideal for technical applications with complex mounting or connection needs. Our clients benefit from full development support, flexible production, and high-quality post-processing – receiving not just a part, but the entire process from a single source.

Casting simulations for smooth production processes

Even in the pre-series phase, we internally test and optimise casting parameters. Using simulation software, we analyse flow behaviour, solidification, and potential stress zones to fine-tune part design for the casting process – before a single part is produced.
Together with our clients’ design engineers and quality managers, we create robust, functional, and cost-efficient die-cast parts – precisely aligned with alloy choices, design requirements, assembly conditions, and finishing needs. This forward-thinking approach is the foundation for durable products and smooth, reliable production workflows.

More than casting – expertise and capabilities for demanding components

Beyond aluminium die casting, HDO offers a comprehensive range of additional services that transform raw castings into ready-to-install system components, including:

CNC machining (milling, drilling, thread tapping)
Deburring, vibratory finishing, blasting
Surface finishing such as powder coating, wet painting, or cathodic dip coating (CDC)
Assembly of modules per customer specifications
Electroplated finishes

These capabilities allow us to meet complex, application-specific requirements with the highest precision – efficiently, reliably, and with consistently high quality and reproducibility. Our highly automated machinery also supports this performance.

Sustainable, strong, and resource-efficient – aluminium die casting by HDO

Sustainability is another strength of HDO’s aluminium die casting. Aluminium is almost infinitely recyclable and can be reused with relatively low energy input. Our production processes are designed for resource conservation, waste reduction, and energy efficiency.
By using recycled aluminium strategically, we contribute to environmentally responsible metal processing – without compromising quality or performance. Additionally, the lightweight nature of aluminium parts reduces energy consumption during transport and throughout the product life cycle – further lowering CO₂ emissions across the entire supply chain.

At HDO, aluminium die casting means more than just production. We support our clients in part design, act as process specialists, and provide complete system solutions. With machine sizes ranging from 260 to 450 tons of clamping force, extensive know-how in aluminium alloys, in-depth expertise in surface finishing, and a dedicated team of engineers and technicians, we develop solutions that stand out in design, functionality, and manufacturing quality.
Our customers particularly value our short communication paths, streamlined processes, fully automated workflows, and the benefit of having a personal point of contact from initial concept to series production and from raw part to fully assembled component.
Compared to zinc die casting, aluminium offers advantages in lightweight construction thanks to its lower density – even if its strength is slightly lower. This allows for material savings and reduced costs. HDO’s reliable electroplating process also opens the door to high-end surface finishes on aluminium parts.

Together, aluminium and zinc offer distinct, application-specific benefits.
Get in touch today and realise innovative die-casting solutions with HDO – we look forward to hearing from you!