How Much Does Die Casting Cost:
What to Expect?

If you’re considering die casting for your next project, understanding the cost is crucial for effective financial planning and overall decision-making throughout the product development process. In this article, we will explore the cost of die casting and factors that drive it. We will also dive into how it compares to the cost of sand casting and CNC machining, and guide you on how to estimate the cost your metal part.

How much does die casting cost?

Die cast quotes are typically divided into two key parts: Die Cost and Per Part Cost.

Die Casting Die Cost – High Upfront Cost, One-Time Expense

The cost of a basic die (or mould tool) for simple parts can range from $3,000 to $10,000. The price for larger, more complex, high-production moulds, or multi-cavity moulds can cost anywhere from tens of thousands to even several hundred thousand dollars.

Die Casting Per Part Cost – Low Unit Cost, Volume Dependent

For small, basic components, per-part costs typically range from $1 to several dollars or more. The price varies depending on the material, size and complexity of the part. For high-volume production runs involving tens of thousands of units or more, economies of scale can reduce costs to as low as $0.10 per part. In general, higher production quantities result in lower per-part costs, material choice also comes into play. To give you a rough idea:

• Aluminium Die Casting Cost typically ranges from $0.2 to $5 per part for simple designs.
• Magnesium Die Casting is generally more expensive than aluminium die casting.
• Zinc Die Casting is often less expensive than aluminium die casting.

How suppliers calculate the cost of your die cast part

How much die casting costs can vary significantly from supplier to supplier, but most companies employ a similar calculation formula. Below is a complete breakdown of the key factors:

• Material Cost: Tooling material and standard parts, such as ejector pins, typically make up 15% to 30% of the total mould cost. High volume or more complex projects will call for more durable and expensive materials.
• Design Cost: This is an essential process that involves having skilled tooling engineers design the mould and create a Design for Manufacturing (DFM) analysis to ensure successful die casting. This generally accounts for 10% to 15% of the total mold cost. 
• Processing Fee and Profit: This includes labour costs, machining and setup costs, overhead, and project margins—these can account for 30% to 50% of the total mould cost. In countries like China, these costs are typically lower due to intense competition, which often forces companies to reduce project margins to remain competitive. Additionally, labour and overhead costs in these regions are much lower.
• Mould Trial Fee: For large and medium moulds, the trial cost is typically kept within 3% of the total mould cost, while for small precision moulds, it is usually within 5%.
• Packing and Transportation Cost: This is generally calculated according to the actual cost or estimated around 3%.