Process development for die-cast components

Perfected development support for optimal die casting solutions

The foundation for high-quality, cost-effective, and fully developed die-cast components is laid at our company long before production begins. At HDO, quality starts in the development phase – with well-thought-out process planning, in-depth design consultation, and a deep understanding of materials, surfaces, and their diverse possibilities.
We look beyond the die-cast component itself and focus on the finished, functional, and decoratively refined end product. After all, your die-cast component is always part of a broader, integrated solution that must perform in its intended environment – technically, economically, and aesthetically.
Our clients benefit from an interdisciplinary team that tightly integrates design, materials engineering, simulation, tooling, surface finishing, and manufacturing to develop customer-specific, efficient, and targeted measures, processes, and methods.

Process development with HDO – a service that makes the difference

HDO offers extensive experience in die-casting-optimised design for decorative components and in structuring all related processes. What many service providers consider the limit of feasibility is often our starting point for innovative solutions.
We see ourselves as your partner – actively contributing to the development of your custom solution. We always consider the end result beyond casting: surface finishing, mechanical post-processing, assembly capability, and technical requirements such as sealing, weight, or conductivity are all incorporated into our development process from the very beginning.

From the initial concept to a ready-for-production component, we support our customers with extensive know-how, creative problem-solving, and a sharp eye for economic feasibility. Our strengths become especially apparent when dealing with complex geometries, tight tolerances, or high demands on surface quality. We identify potential across all relevant process steps up to the finished part, allowing us to increase efficiency, reduce costs, minimise errors, and continuously improve production for our clients.

Die-cast-friendly product design – the key to production readiness

A key part of our process development is providing design consultation for optimal shaping of decorative parts for zinc and aluminium die casting. Early in the project, our experts review the feasibility of proposed geometries based on the customer’s requirements and assist in adjusting the design. Our goal is to develop economically viable, process-reliable, and production-ready solutions in a clearly defined process that meet both functional and aesthetic demands.

We analyse wall thickness transitions, draft angles, the positioning of parting and injection lines, as well as the integration of functional features such as threads, mounting points, or surface textures. We also consider specific requirements such as sealing, electrical conductivity, material strength, or weight reduction – always in line with applicable standards and industrial norms.
The result: we integrate many functions directly into the casting process, which significantly reduces machining effort, part cost, and assembly time. No matter the industry, whether standard parts or custom components – we approach process development with the same dedication to innovation and individuality as we do the manufacturing of the final product.

Simulation, analysis, validation – secured from the start

To ensure the reliability of our development process, we use state-of-the-art simulation tools that allow us to digitally map, precisely design, and later optimise the die casting process. Using flow simulations and thermal management analyses, our specialists identify potential weak points early and correct them well before production begins.
This proactive approach not only ensures traceable structures and high-quality end results but also delivers significant time and cost savings during implementation. Our clients benefit from shorter development cycles, fewer iteration loops, and a smooth transition from prototype to series production with the best possible process integration.

Special solutions for complex requirements

We regularly receive project enquiries that other providers in the market consider unfeasible. In precisely these cases, our process development demonstrates its true strength: through creative problem-solving, experience with special requirements, and a high degree of flexibility, we are able to implement even highly demanding parts economically and with assured quality.
Whether it’s highly complex geometries with tight radii, ultra-fine surfaces for decorative applications, or integrated functional elements at the micrometre level – our development team will work with you to find the right solution.

Interfaces to follow-up processes

One of HDO’s unique advantages is our tight integration between die casting development and follow-up processes such as surface finishing, machining, coating, laser engraving, or assembly. Since we don’t just cast but also electroplate, post-process, and partner with expert coaters, we take a cross-process, full-solution approach from the start – preventing problems down the line and ensuring a smooth transition into series production.
This means that as early as the design phase, factors such as coating buildup, plating compatibility, decorative effect, and deformation behaviour due to coating processes are carefully considered.
This holistic approach allows us to establish a reliable series production process for even the most complex components with both decorative and functional surfaces – without unexpected issues in the coating process.

Collaborative, transparent, solution-oriented

Working with HDO on process development is defined by transparency, open communication, and a shared goal: achieving the best possible product in the highest possible quality – cost-effective, technically sound, and sustainably manufacturable.
Our customers value the collaborative spirit, deep technical expertise, and willingness to think beyond conventional standards. Especially during early project phases, we make a critical contribution to successful product development.

HDO – where innovation takes shape

Whether starting from scratch or optimising an existing process: process development at HDO is far more than a technical interim step. It is an integral part of our commitment to quality and innovation.
With a dedicated team, advanced development tools, and a deep understanding of the entire value chain – from design to surface – we lay the foundation for successful products.
Talk to us about your project. We’d be happy to give you a more detailed overview of how your idea can become a production-ready, economically viable, and innovative component – tailored exactly to your needs.