Custom Aluminium & Zinc Die Castings, Engineered to Spec
Die casting turns one tool into thousands of precise, repeatable metal parts. P&A International engineers and delivers custom aluminium and zinc die castings — housings, enclosures, structural parts and thermal components — with machining, finishing and assembly managed end-to-end to your drawing, tolerance and target cost.
As an engineering-led contract manufacturer founded as an engineering consultancy, we assign one dedicated engineer to your project from die design to free off-tool samples, then scale into volume through our vetted partner-factory network, where every supplier is ISO 9000 certified or better.
consultancy + manufacture
per project, end-to-end
before mass production
every supplier certified or better
one-off to high volume
What we deliver
Aluminium die castings
ADC12 / A380 housings, brackets and structural parts with good strength-to-weight and EMI shielding, from grams to large casings.
Zinc die castings
Zamak parts with fine detail, thin walls and excellent platability for precision components, connectors and decorative parts.
Die-cast thermal parts
Die-cast heatsinks, enclosures and heat-exchanger bodies that combine cooling features with structural function in one part.
Machining & finishing
CNC machining of sealing faces and bores, plus shot-blast, powder coat, painting, plating, leak testing and assembly.
Engineering capability
- Die design & die-making within the partner-factory network
- Alloy selection — ADC12 / A380 / A360 aluminium and Zamak zinc
- Cold- and hot-chamber casting; partner machines from roughly 500 to 3,500 tonnes
- Casting weights from a few grams to around 18 kg
- Pressure-tight and low-porosity casting where the application requires it
- CNC machining of sealing faces, bores and tapped holes
- Finishing — shot blast, powder coat, painting, anodise (on suitable alloys), plating
- Leak testing, impregnation, inserts, assembly and kitting
At a glance
| Alloys | ADC12 / A380 / A360 / A413 aluminium; Zamak 3 / 5 zinc |
| Machine size | Partner factories run roughly 500 – 3,500 tonne machines |
| Part weight | From a few grams to around 18 kg |
| Wall thickness | Typically 2 – 4 mm for aluminium; thinner for zinc |
| Secondary | CNC machining, tapping, inserts, assembly |
| Finishing | Shot blast, powder coat, paint, plating, anodise (suitable alloys) |
| Samples | Free off-tool samples + quality-assessment reports before mass production |
| Quality | Every supplier in our network is ISO 9000 certified or better |
Why engineers & buyers choose PA
For design engineers
A true design partner — one dedicated engineer, die design and gating strategy, wall-thickness and draft review, and porosity control for pressure-tight parts. We get involved at the design stage to protect the tool and the part for the life of the project.
For purchasing
Low-risk scalability — free off-tool samples before mass production, single- or multi-cavity tooling matched to your volume, target-cost DFM, a single point of contact, and a vetted ISO 9000+ partner network managed end-to-end by P&A.
3 easy steps to get started
Send us your part
Share a 3D model or drawing, alloy and volume — or just the application. One dedicated engineer reviews it and confirms the casting approach.
Proposed design & quote
You receive a proposed casting and tooling strategy with indicative pricing — typically within 48 hours — to review and refine together.
Samples & production
Free off-tool samples with quality-assessment reports. On approval, your order is cast, machined, finished, inspected and shipped through our partner network.
Applications
Consumer electronics & appliances · LED lighting · telecom & networking enclosures · automotive & e-mobility · industrial equipment · power & energy systems · thermal management.
Die casting is one part of our aluminium and metal capability. Explore the aluminium design & fabrication hub, custom aluminium extrusions for profile-based parts, custom heatsinks including die-cast coolers, and our existing die casting service page.
Designing a better die casting
A few early decisions shape every die casting — sharing this detail lets us quote and prototype faster:
| Alloy | Aluminium (ADC12/A380) for strength-to-weight and thermal/EMI; zinc (Zamak) for fine detail, thin walls and plating. |
| Wall thickness | Keep walls uniform (typ. 2–4 mm in aluminium); core out thick sections or add ribs to avoid porosity. |
| Draft & radii | Draft on all faces and generous corner radii protect the tool and improve fill. |
| Tolerances | Cast to general tolerances; call out only the few critical features for CNC — it controls cost. |
| Porosity | For pressure-tight parts say so up front — it drives gating, process and any impregnation. |
What to send us for a fast, accurate quote
The more of this you can share, the quicker we can return a proposed design and price:
- A 3D model (STEP/IGES) or drawing, with critical dimensions
- Alloy preference — aluminium or zinc — if known
- Approximate part size, wall thickness and weight
- Pressure-tightness, machining and finishing requirements
- Target cost and annual volume or call-off pattern
- Any existing tool to transfer, or a reference/sample part
Working from a sample or an existing tool is fine — our engineer will assess it and propose the best casting and machining route.
📄 Download the die casting RFQ checklist & selection quick reference (PDF)
Get a quote
Send your model, drawing or part idea and one dedicated engineer will reply — typically within 48 hours — with a proposed casting design and indicative pricing. No project too big or too small.
One dedicated engineer reviews every enquiry and replies with a proposed design and indicative pricing. Your details are used only to respond to your enquiry. Prefer email? support@pa-international.com.au