Finding a die casting manufacturer that handles both aluminum and zinc under one roof is difficult. Most shops specialize in a single material, and buyers end up coordinating with separate vendors for different components.

At RFQUSA, our directory is built on a strict vetting process designed to connect buyers with manufacturers they can rely on. Every company we list on our site is evaluated for its reputation, demonstrated capabilities, and track record of client satisfaction before we approve it.

Read on to learn why we strongly recommend PHB Corporation for aluminum and zinc die casting manufacturing.

Get a Quote for Aluminum and Zinc Die Casting

A Century of Aluminum & Zinc Die Casting Manufacturing

PHB brings over 100 years of Aluminum and zinc die casting manufacturing experience to every project they undertake. They operate 58 aluminum presses ranging from 250 to 2000 tons and zinc presses ranging from 100 to 800 tons across 750,000 square feet in Pennsylvania. This dual-metal capability means buyers get both materials from a single manufacturer rather than splitting orders between separate foundries.

Both hot-chamber zinc die casting and high-pressure aluminum die casting are run at their facility. The 500-employee operation fabricates a wide range of components, including automotive lighting and powertrain parts, military hardware, aerospace assemblies, and industrial equipment. Their facility produces everything from prototype runs to high-volume production batches.

Aluminum Die Casting

Complex geometries and thin-walled components are produced using high-pressure die casting processes. Process monitoring, press-side imaging, and robotics extend tool life and reduce cycle times across production.

Aluminum die casting alloys deliver lightweight construction with high dimensional stability, good corrosion resistance, and high thermal and electrical conductivity. PHB casts aluminum alloys 360, 380, 383, 413, and A304, as well as zinc-aluminum alloys for applications requiring higher strength.

Zinc Die Casting

The lower melting point allows hot-chamber zinc die casting to run faster production cycles than cold-chamber aluminum processes. The lower melting temperature promotes longer die life compared to aluminum tooling. PHB casts Zamak 3, 5, and 7 alloys plus ZA-8, ZA-12, and ZA-27 zinc-aluminum alloys.

Zamak alloys provide high ductility, impact strength, and easy plating for appliance, automotive, and industrial hardware. ZA alloys have a higher aluminum content, resulting in increased strength and hardness. These zinc-aluminum formulations provide bearing properties where load-bearing performance matters.

Turnkey Manufacturing: From Tool Design to Final Assembly

Die casting programs that split work between separate tool shops, foundries, machine shops, and finishing houses accumulate delays at each vendor handoff. Quality issues become difficult to resolve when accountability fragments across multiple suppliers with conflicting schedules and priorities. Consolidating tool design, die casting, CNC machining, surface finishing, assembly, and packaging at a single facility eliminates these dependencies.

Programs that typically require coordinating three to four vendors run through one facility under unified quality control. Inter-vendor shipping delays disappear, and markup at each handoff gets eliminated. Design changes get implemented across all production steps without re-coordinating multiple shops.

PHB Quality Control Systems

PHB’s extensive quality control systems combine certified processes with advanced inspection equipment to verify every component before shipment. IATF 16949 certification backs all manufacturing at PHB, and the operation applies APQP, FMEA, PPAP, MSA, and SPC core tools across production. CMM precision measurement equipment conducts first article inspections, in-process checks, and final inspections to verify dimensional accuracy.

Cognex vision systems verify the presence or absence of features and detect defects in real-time during production. The FARO Edge ScanArm provides non-contact 3D scanning for reverse engineering, direct CAD comparison, and inspection of complex castings and tooling. Six Sigma Black Belt and Green Belt projects drive variation reduction through design of experiments, lean activities, and proactive defect prevention.

MAGMAsoft® Mold Flow Simulation and Design Optimization

MAGMAsoft® simulation software optimizes tool design and predicts casting quality before cutting steel for production tooling. The simulation models mold-filling behavior, solidification patterns, thermal stresses, distortions, and potential locations of porosity. Design improvements that reduce trial-and-error during tool debug emerge from this analysis.

Their engineering staff engages early in part design using PTC Creo to verify manufacturability and reduce costs before tooling begins. Draft angles, wall-thickness variations, and gating locations that could cause defects or increase costs are caught during DFM reviews. Multi-cavitation design and material selection decisions get validated through simulation and reduce costs on both existing programs and next-generation development.

ITAR-Compliant Manufacturing for Defense and Aerospace Programs

ITAR registration allows PHB to manufacture components for defense and military programs requiring controlled access. Government and military work is completed, and parts subject to export restrictions for U.S. government contractors are produced in compliance with ITAR. Die casting shops unable to meet the security, documentation, and facility requirements for defense work lack this registration.

PHB solved a complex automotive lighting challenge requiring six heat sink pads per casting with profile tolerances within 0.4mm across 102 critical features. What previously required four separate castings per headlight assembly got consolidated into a two-casting design using MAGMAsoft simulation and precision machining. The solution reduced part count and simplified assembly for the automotive lighting manufacturer.

Get a Quote From an Industry-Leading Die Casting Manufacturer

Running both aluminum and zinc without coordinating separate foundries requires the right equipment and expertise under one roof. Good manufacturers invest in dual-metal capability instead of forcing buyers to manage multiple vendors.

PHB eliminates multi-vendor coordination by running aluminum and zinc die casting with turnkey services from tooling through finishing. Buyers get single-point accountability for both materials under IATF 16949 and ITAR certification without managing separate foundries.

Get a Quote for Aluminum and Zinc Die Casting