The function and use of the final product will dictate die-casting alloy selection. For example, if the component requires high strength and corrosion resistance, an aluminum or copper based alloy could be an effective choice. Another consideration is production volume. With proper maintenance, aluminum die-casts can have a life of approximately 100,000 cycles, while zinc molds can last up to one million cycles before being replaced. For long-term, high-volume production, it may be more cost-effective to use alloys that maximize the life of the molds.  

When considering various fabrication methods, it may be helpful to examine the advantages and disadvantages of using a die-casting process.

Potential advantages include:

Dimensional Strength: die-casting parts are stronger than plastic components.

Rapid Production: die-cast components can be produced in high volume with relatively little tooling or machining.

Smooth Surfaces: the die-cast process can create finished parts with curved or seamless surfaces.

Accuracy: die-casting parts can be created with close adherence to specifications.

Possible disadvantages include:

High Volume: smaller production runs may reduce cost-effectiveness.

Limited Metal Fluidity: alloy malleability varies, which can limit the complexity and shape of the finished product.

Size and Weight Limits: a casting machine’s capacity limits the range of product dimensions.