Understanding Wall Thickness in Die Casting: Why Uniformity Matters

Wall thickness may seem like a basic design choice—but in die casting, it’s one of the most critical parameters affecting part integrity, cycle time, tooling durability, and cost. Getting it wrong can lead to warping, porosity, or premature tool failure.

What Is the Ideal Wall Thickness?

For aluminium die-cast parts, a typical wall thickness ranges between 2.5mm to 5.0mm. For zinc, thinner walls are possible—down to 1.0–1.5mm—thanks to its better fluidity.

However, there’s no one-size-fits-all. The ideal thickness depends on:

• Alloy type

• Part size and complexity

• Required mechanical strength

• Surface finish requirements

• Tolerances and downstream machining

Referencing NADCA Guide 2015 Edition

Why Uniform Wall Thickness Matters

1. Reduces Warpage and Sink Marks

   Uneven sections cool and solidify at different rates. This creates stress, shrinkage voids, and dimensional instability.

2. Improves Metal Flow

   Abrupt changes in thickness cause turbulence or trapped gas. Smooth, consistent wall design enables complete filling under pressure.

3. Lowers Tool Stress

   Sections that solidify too slowly can “stick” to the die, increasing ejection force and reducing tool life.

4. Enhances Machining Stability

   A consistent wall avoids chatter and uneven force during drilling, tapping, or milling operations.

At LVIO Precision, our DFM (Design for Manufacturability) service always includes wall thickness evaluation—offering guidance to optimize both casting quality and tooling efficiency.

We can suggest local thickening, corner radius optimization, or coring strategies to help you meet your weight and cost targets without compromising part reliability.