Department of aluminum die-casting

Aluminum and zinc die-casting foundry

Automated high-pressure die-casting cells for aluminum products

Aluminum is the ideal solution for situations requiring strength, good mechanical and chemical properties, enormous conductivity, high corrosion protection and weight savings. The most modern process technology is present in our hall and equipped with the latest in aluminum die-casting machines and smelting furnaces.

The equipment to produce these parts consists of cold chamber die-casting machines from 420 up to 840 tons. This allows to produce parts up to 12 kg weight and up to 3300 cm2 projected area. All the machines are completely integrated in die-casting islands including dosing furnaces, robot die face lubricators and robotic extractors.

The advantages of the production of high-pressure aluminum die casting parts are the following:

  • Complicated shape near to the final shape which reduces the machining cost
  • Very good mechanical properties
  • Good mechanical surface roughness
  • Every kind of coating (powder coating, liquating coating, metal plating)
  • Good machinability (lathing, milling, drilling, tapping)
  • Recyclable material
  • Very big productivity

Automated die-casting cell for zinc products

Thanks to optimized casting processes, even the most delicate die-cast zinc parts, and even those with extremely thin walls, can be produced with superior properties. Maximum dimensional accuracy, savings in weight and materials, as well as superb surface properties are all the results of many years of experience and optimizing the process. With the use of a number of ZAMAK alloys, there is an unimagined spectrum of diversity in zinc die-casting.

Hot chamber machines by 80 ton clamping force under CNC control are used to produce precision castings weighing up to 3,500 g. These units exhibit clamping power up to 2,200 kN. Modern smelting plant works in conjunction with integrated liquid charging at the automated casting machines operating under real-time control. Equipped with electrically heated, two-chamber furnaces, the configuration ensures uniform temperature in the zinc alloys.

Vacuum- and squeeze-casting

Other die-casting processes such as vacuum- and squeeze-casting are also possible.

Thixo-casting (Semisolid SSM)

Semi-solid metal processing enables the manufacturing of components with complex shapes, with thin walls, with good mechanical properties and with a high dimensional tolerance and accuracy. The thixo-casting process uses stirring of the melt during the solidification of a continuous cast bar to obtain the globulitic microstructure.

The properties of the parts made by the thixo-molding procedure are the following:

  • Complicated shape with extra thin walls near to the final shape which reduces the machining cost
  • Ultra-high mechanical properties
  • Impenetrable from ultra-high frequency, suitable for armor housings
  • Ultra-low surface roughness
  • Weldability
  • Suitable for heat treatment
  • Every kind of coating (powder coating, liquating coating, metal plating)

The additional equipment which is available for such kind of parts is the following:

  • 6 axis robot and
  • 8 stations induction furnaces for the thixo-alloy
  • Control Unit

Quality control laboratory and assurance

Our goal is to guarantee top quality for your precision die cast components. To attain this, our entire production process is monitored and documented continuously from the outset using the latest testing and measurement technology, During the tool implementation process, the various components pass through a number of different testing stations. We employ state-of-the-art 3D-measurement systems and produce software-generated measurement reports.

Our quality control laboratory consists of:

  • X-ray inspection for porosity and voids (cavities) according to individual customer specifications
  • 3D measuring - Ensure exact dimensions of up to 4 μ, tactile control of defined characteristics, for series production in the area of casting and machining as well as for initial sample inspection
  • Spectrograph - Standard testing of alloy components to ensure material safety

Quality management

Quality management is a core element in our work processes. From initial order placement through to delivery, our work is carried out extremely meticulously and in compliance with stringent quality criteria on every project.

DROMEAS is certified to ISO 9001, ISO 14001, OHSAS 18001, ELOT 1801, PEFC, FSC and EMAS. In addition, ISO TS 16949 is in progress.

Surface finishing and assembly

Professional surface treatment capabilities further add to the range of high-quality finishes for die-cast components. We can provide decorative blasting and bright polished, matte and brushed surfaces – the ultimate in surface finishing.

Top-class finishing

Top-class linishing, belting, buffing, polishing is performed among others by our robotic cells keeping high quality standards to the processable surfaces.

Powder coating

Powder coating is a colour coating method in which we apply the finest solid particles based on polyester and epoxy resins to an electrically conductive workpiece. The particles adhere to the electrostatically charged surface and are then fused to a smooth film in a kiln at up to 220°C. Powder coatings contain neither solvents nor heavy metals and offer an incomparable range of colours and shades. They offer a variety of ways to decorate the workpiece and protect it from corrosion at the same time.

Trovalising / Vibratory grinding

Rounding, grinding or smoothing are processes with which we can machine the surface of cast blanks in light of their later use during vibratory grinding or trovalizing. To do this, blanks are placed in a vibrating container with special abrasives. The movement of the abrasive particles in the container causes material to be removed, which is necessary to produce the desired surface quality. The result can be varied selectively depending on the abrasive used. Vibratory grinding or trovalizing is especially suitable for small workpieces.


Using sandblasting, we prepare the surface for final treatment after the deburring of our die-cast blanks. Blasting media is directed at high speeds against the surface of the workpiece – this treatment achieves maximum homogeneity, optimum adhesion and surface texture. As a result, the aluminum die-cast part is optimally prepared for final surface treatment, for example with powder coating, which serves for both decoration and corrosion protection.

Other surface operations including advanced washing using agents such as modified alcohols and CNC machining and are also available. Sub-assemblies are also handled based on customer requirement.