High Precision Die Casting Services
For more than a century, providing the highest quality zinc die cast parts to customers throughout the United States and around the world
About Us
Since 1908, DeCardy Diecasting has been providing the highest quality zinc die cast parts to customers throughout the United States and around the world.
Our business started at the turn-of-century casting components for American Flyer and other manufacturing companies. Still family owned and operated, our parts today can be found in the critically demanding, high-stress environments of motorcycles, cars and trucks to the unforgiving tolerances of precision medical equipment and electronic testing devices.
The DeCardy Difference: Customers choose us for our engineering expertise and concurrent engineering process that resolves aggressive design challenges. Our central US location eliminates logistical, communication, and quality issues of offshore sourcing. Our size and full-service capabilities make us an agile, reliable partner.
The CELL Method: Every DeCardy project is assigned to a CELL that includes all personnel required to complete it. Unlike traditional assembly-line systems, this approach optimizes quality and scheduling control, resulting in cost savings ranging from 18% to 54%.
Why Choose Zinc Die Casting?
Zinc die casting offers numerous cost and production advantages for industries ranging from complex medical and electronic applications to automotive components.
Zinc is particularly economical for small parts, with a low melting point that promotes exceptionally long die life - it's not unusual to cast more than a million parts from a single tool. The ability to cast multiple features in one process, combined with reduced friction and abrasion on tool surfaces, significantly lowers overall manufacturing costs.
Compared to plastic injection molding, zinc castings are much stronger while providing closer tolerances and thinner part walls. Versus stamping and forging, zinc casting produces more complicated shapes with better accuracies and different wall thicknesses with less labor. And compared to machining, zinc die casting produces complex shapes that would require many different set-ups and sophisticated tools.
High ductility • Dimensional stability • High impact & tensile strength • Thin wall sections • Close tolerances • Temperature resistant
Long tool life (1M+ parts) • Multiple features in one process • Low melting point • Good electronic signal shielding
Chrome & nickel plating • E-coating • Powder coating • Chromating • Multiple surface finishes
Our Services
High Pressure Zinc Die Casting
Advanced zinc die casting with tolerances of ± 0.0005" for difficult and complex parts. Zinc's high ductility, dimensional stability, and superior strength-to-weight ratio enable thin wall sections and close tolerances. Capabilities include parts up to 24" in size, shot weights up to 2 lbs, and 250-700 shots per hour. Long tool life (1M+ parts per die) ensures cost-effective production. Utilizing Techmire, Frech, and Roto-Finish equipment for miniature to large components across electronics, medical, automotive, and industrial applications.
Secondary Services
Comprehensive in-house finishing, assembly, and packaging services. Zinc alloy provides a highly stable base for a range of finishing processes and materials. Finishing includes deburring, semi-polishing via Vibramilling, chrome and nickel plating (electro and electroless), e-coating, powder coating, chromating, and precision grinding. From partial to full assembly with customized packaging and delivery solutions - completing and shipping production-ready parts from one location.
Design Assistance & Concurrent Engineering
DeCardy's developed concurrent engineering process optimizes quality and productivity from concept to production. Services include design optimization, flow and thermal casting analysis, prototyping, tool maintenance and modification, and SolidWorks file support. Our engineering expertise ensures cost-effective, manufacturable solutions with typical lead times of 4-6 weeks.
Quality Assurance
ISO 9001:2015 and ISO 13485:2016 certified facility with comprehensive quality assurance regimens. Every part undergoes thorough testing and inspection including optical comparator testing. Member of NADCA (North American Die Casting Association) and TMA (Tooling and Manufacturing Association). Award-winning parts recognized at NADCA's International Die Casting Competitions.
Our Work
Showcasing precision zinc die casting across various industries
Automotive Components
Precision die cast parts for high-performance vehicles
Medical Equipment
ISO 13485 certified precision components
Electronic Housings
Complex geometries with tight tolerances
Finished Parts
Chrome plating, powder coating & more
Industrial Applications
Heavy-duty components for demanding environments
Intricate Designs
Showcasing advanced die casting capabilities
Award-Winning Projects
Spotlight Head Housing
Developed for police, emergency, military and commercial vehicles. NADCA 23rd International Die Casting Competition award winner. Achieved 60% reduction in pre-plating buffing operations and 36% overall cost savings through innovative gating and design improvements.
Pogo Block Assembly
Miniature high-performance test equipment component for microchips weighing less than 0.00090 lbs. NADCA 22nd Competition award winner. Replaced CNC machined aluminum with die cast zinc, reducing part costs by 95% with savings exceeding $1.2 million.
Fuel Injection Bracket
Throttle stop bracket for high-powered motorcycle engines. NADCA 22nd Competition award winner. Converted multi-part welded assembly to single die cast component, reducing assembly operations by 70% and costs by 76% using innovative slide-within-slide tooling.
Quality Certifications
DeCardy Diecasting is committed to maintaining the highest quality standards in the industry.
We are proud to be certified under both ISO 9001:2015 and ISO 13485:2016, demonstrating our commitment to quality management systems and medical device manufacturing excellence.
Our certifications ensure that every part we produce meets rigorous quality standards, from initial design through final delivery.