Assembly by Die Casting is used as the joining medium to assemble multiple small components up to 6 in. (150 mm) in diameter, and as the production method to form additional components directly on the assembly.

Design and manufacturing engineers looking for a better way to produce small component assemblies can imagine the following scenario.

Components to be assembled are placed inside a custom assembly tool containing a cavity where the components intersect. Molten zinc alloy is then injected under pressure into the cavity, where it solidifies in milliseconds, locking the components. Moments later, the tooling ejects the completed assembly, which emerges free of burrs and flash.