Shenzhen Alu Rapid Prototype Precision Co., Ltd.
Industry News
Die-Cast Aluminum Cost Breakdown
Pricing depends on several factors — here's a comprehensive overview:
Part Price by Volume
Production Volume | Typical Cost Per Part |
Prototype (1–10 pcs) | $50 – $500+ per part |
Low volume (100–500 pcs) | $5 – $50 per part |
Medium volume (1,000–10,000 pcs) | $1 – $10 per part |
High volume (50,000+ pcs) | $0.50 – $5 per part |
Tooling / Mold Cost (Biggest Upfront Cost)
Mold Type | Cost Range |
Simple single-cavity mold | $3,000 – $10,000 |
Medium complexity mold | $10,000 – $30,000 |
Complex multi-cavity mold | $30,000 – $80,000+ |
Large/high-precision mold | $50,000 – $150,000+ |
Tooling is a one-time cost amortized over the production run. At high volumes, mold cost per part becomes negligible.
Cost by Machine Size
Machine Tonnage | Application | Hourly Rate |
100–400 ton | Small parts (connectors, brackets) | $40 – $80/hr |
400–900 ton | Medium parts (housings, covers) | $80 – $150/hr |
900–2,000 ton | Large parts (automotive) | $150 – $300/hr |
2,000+ ton | Very large structural parts | $300 – $600/hr |
Cost by Geography
Region | Mold Cost | Part Cost (per unit, med. vol.) |
USA / Canada | $15,000 – $80,000 | $3 – $15 |
Western Europe | $12,000 – $70,000 | $3 – $12 |
China (Shenzhen/Dongguan) | $3,000 – $20,000 | $0.80 – $5 |
India | $4,000 – $25,000 | $1 – $6 |
Mexico | $6,000 – $30,000 | $1.50 – $7 |
What Drives Cost Up
Complex geometry — Slides, cores, undercuts add mold complexity
Tight tolerances — More precise machining and inspection
Thin walls — Harder to fill, higher scrap rate
Large part size — Requires bigger machine and more material
High surface finish — Additional polishing and plating
Multiple cavities — Higher mold cost but lower per-part cost
Secondary operations — CNC machining, tapping, drilling after casting
What Drives Cost Down
Simple geometry — Two-part mold with no slides
High volume — Amortizes tooling cost
Sourcing from China — Significantly lower labor and overhead
Standard tolerances — Less inspection and rework
Design for manufacturability (DFM) — Optimized draft angles, wall thickness
Full Cost Breakdown Example
Example: Medium-complexity aluminum housing, 5,000 pcs from China
Cost Item | Amount |
Mold/tooling | $8,000 (one-time) |
Die casting per part | $1.50 |
CNC machining per part | $0.80 |
Surface finish (anodize/paint) | $0.50 |
Material (aluminum) | $0.60 |
Total per part | ~$3.40 |
Total project cost | ~$25,000 |
Common Aluminum Alloys & Material Cost
Alloy | Composition | Cost | Common Use |
A380 | Al-Si-Cu | Low | General purpose, most common |
A360 | Al-Si-Mg | Medium | Better corrosion resistance |
ADC12 | Al-Si-Cu | Low | Automotive, electronics |
A413 | Al-Si | Medium | Pressure tightness |
383 | Al-Si-Cu | Low | Complex thin-wall parts |
Aluminum ingot currently trades around $2,200 – $2,600 per metric ton, but alloy and processing premiums add to this.