On a daily basis and practically everywhere, we deal with die-casting aluminum products. Parts for automobiles, power tools, gear housings, and structural components. #aluminiumdiecasting #aluminium #howitsmade It is lightweight, strong, resistant to water, and oxide-proof.

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We went to the Metazel production facility to learn about the process of die-casting aluminum, which is one of the most advanced pressure die-casting foundries in Poland and one of the largest in Europe.

00:39 Inside Factories: Metazel
Our product line includes pressure castings of aluminum and zinc alloys for a variety of industries, including automotive, household appliances, construction, electrical and power tools, and many more.

00:59 Aluminium melted
This one is required for manufacturing reasons, which must first be melted in induction furnaces. These furnaces are capable of melting 1.5 tons of raw material in 45 minutes. The melted substance is refined. The refiner is mounted on top of the furnace, and its revolving head delivers argon to the metal treatment bath. Argon ascends, carrying all gases and impurities with it, which are then collected by the melter.

Aluminium in this condition is subsequently moved to melting facilities and fed into machine furnaces. Their function is to keep metal liquid.

02:15 The most advanced casting technologies are used at Metazel Foundry. A robot with a 1 gram precision harvests material using a customized pipette. The pipette sinks beneath the liquid aluminum surface.

As a result of the foregoing, metal injected into the mold is free of contamination caused by air contact.

02:37 Die-casting method
Another way of casting is to use a special ladle to pour into the filling chamber. The material is then forced into the mold and pressed. The whole interior of the mould is filled with liquid metal. The aluminum solidifies and the mold expands.

03:07 Metal structure check
Once we receive aluminum castings, we perform a rentgenographic test to examine the metal structure. Contamination, air bubbles, or discontinuities in the metal structure all have an impact on detail endurance. That is why this examination is crucial.

The cast detail is cleaned and tumble finished or shot-blasted. It is then transferred to the machining department, where it is processed in three-axle, horizontal and vertical machining centers, and NC-controlled turning machines. Threading and turning are completed, and details are machined.

Final samples? Details are sent to the control department, which performs the special quality testing. Measurements with an accuracy of up to 3 microns, endurance and strength testing, and chemical composition analysis of aluminum are all carried out.

We ship die-castings to customers only after we are confident that they meet the most stringent quality standards.


We're here to find out what it's like to work in this field. The popular TV show "How It's Made?" had an effect on this project. He became well-known because of the Discovery TV channel.
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