CNC vs Die Casting Cost Comparison (2026)
|
Metric |
CNC Machining |
Die Casting |
Source |
|
Per-piece cost, 50 pieces |
$25–$80 |
$50–$120 + tooling amort |
Yuqing data |
|
Per-piece cost, 500 pieces |
$15–$50 |
$8–$30 + tooling amort |
Yuqing data |
|
Per-piece cost, 5,000 pieces |
$8–$25 |
$2–$8 + tooling amort |
Yuqing data |
|
Per-piece cost, 50,000 pieces |
$5–$15 |
$0.50–$3 + tooling amort |
Industry data |
|
Tolerance |
±0.025–0.1 mm |
±0.1–0.3 mm |
Process capability |
|
Material options |
All metals + plastics |
Zinc, aluminum, magnesium, brass |
Die casting limits |
|
Min. wall thickness |
0.5 mm |
1.0–1.5 mm (depending on material) |
Process limit |
|
Max. part size |
6 m (gantry) |
~600 × 600 mm typical |
Machine envelope |
|
Internal complexity |
Limited (straight holes, simple pockets) |
High (complex 3D shapes) |
Process capability |
|
Surface finish (as-produced) |
Ra 0.8–3.2 μm |
Ra 1.6–6.3 μm |
Process default |
|
Lead time, tooling |
None |
6–12 weeks |
Tooling lead time |
|
Lead time, parts (after tooling) |
7–15 days |
4–8 weeks (production rate) |
Yuqing data |
What Is Die Casting?
Die casting injects molten metal into a steel mold (die) under high pressure. The metal solidifies in seconds, and the part is ejected. The process is highly repeatable and very fast for high-volume production.
There are two main types:
Hot-chamber die casting — for zinc, magnesium, and low-melting-point alloys. Cycle times: 10–30 seconds.
Cold-chamber die casting — for aluminum and high-melting-point alloys. Cycle times: 30–120 seconds.
What Is CNC Machining?
CNC machining removes material from a solid block (billet) using rotating cutting tools. The part is built up by subtraction — every feature is cut, drilled, or milled from the starting stock.
The process is flexible (any geometry the machine can reach), accurate (±0.025 mm), and requires no tooling beyond workholding fixtures.
When to Choose CNC Machining
CNC machining wins in these scenarios:
1. Prototype and low-volume production
For runs under 500 pieces, die casting tooling ($5,000–$50,000) can't be amortized. CNC has near-zero tooling cost.
2. Tight tolerances
CNC holds ±0.025 mm consistently. Die casting typically achieves ±0.1–0.3 mm. For parts requiring precision interfaces (bearing seats, sealing surfaces), CNC is required.
3. Material certification
CNC parts have full mill certifications. Die cast parts rely on the alloy supplier and process control — certification is less rigorous.
4. Small, simple parts under 50 mm
For small parts, CNC cycle times are fast (under 5 minutes). Die casting tooling cost is hard to justify at low volumes.
5. Materials not suited for die casting
Steels, titanium, copper, and engineering plastics cannot be die cast. For these materials, CNC is the only option.
6. Design changes during development
CNC can adapt to design changes within hours (reprogramming). Die casting requires new tooling ($5,000–$50,000) and 6–12 weeks lead time for any geometry change.
7. Functional testing and validation
Before committing to $30,000 in die casting tooling, you typically want 50–500 CNC prototypes to validate the design works as intended.
When to Choose Die Casting
Die casting wins in these scenarios:
1. High-volume production (>1,000 pieces)
Tooling cost amortizes quickly. At 10,000+ pieces, die casting per-piece cost is 80–95% lower than CNC.
2. Complex 3D geometry with internal features
Die casting can produce features impossible to machine — internal channels, complex curves, undercuts, fine details. CNC has tool access limits.
3. Thin walls and lightweight structures
Die casting can produce walls down to 1.0 mm (some alloys even thinner). CNC struggles below 1 mm for production parts.
4. Castable alloys (zinc, aluminum, magnesium)
For parts in these alloys, die casting is often the most cost-effective process.
5. Consumer products with cosmetic requirements
Die casting produces consistent surface finish (Ra 1.6–3.2 μm) ideal for cosmetic parts (appliance housings, automotive trim).
6. Tight production rate requirements
A die casting cell can produce 100–500 parts per shift. CNC production is slower per machine (typically 50–200 parts per shift depending on cycle time).
Crossover Analysis
The crossover point (where die casting becomes cheaper than CNC) depends on:
Tooling cost: simple parts = $5,000; complex = $50,000+
CNC cycle time: 5 min vs 30 min vs 60 min per piece
Die casting cycle time: 10–60 seconds (much faster)
Material cost: CNC billet vs die casting alloy (often similar)
Typical crossover:
|
Part Complexity |
CNC Cycle Time |
Die Casting Crossover |
|
Medium (10 features) |
15 min |
~800 pieces |
|
Complex (20+ features) |
30 min |
~400 pieces |
|
Very complex |
60+ min |
~200 pieces |
The crossover drops as
CNC cycle time increases. For complex parts, even small production runs may favor die casting.
Real Cost Comparison (Yuqing Quote, 2026)
A buyer requested an aluminum enclosure for an industrial sensor:
Geometry: 80 × 60 × 40 mm, 4 mounting bosses, 1 connector pocket, 1 cable gland hole
Quantity: 1,000 pieces/year for 3 years (3,000 lifetime)
Tolerance: ±0.1 mm
Option A — CNC machining (only):
Per piece: $22
3,000 pieces × $22 = $66,000
Option B — CNC prototypes + die casting production:
50 CNC prototypes for validation: 50 × $45 = $2,250
Die casting tooling: $18,000
Die casting production: 3,000 × $4.50 = $13,500
Total: $33,750
Hybrid approach saved 49%. The CNC prototypes validated the design (catching 2 tolerance issues), then die casting scaled economically.
Pure CNC would have been the right call if:
Total volume was <500 pieces (tooling wouldn't amortize)
Tolerances were tighter than ±0.05 mm
Material was steel or titanium (not die castable)
Design was still being iterated
Hybrid Workflow (Best Practice)
For most production parts, the best practice is:
Design validation phase: CNC prototype run of 10–50 pieces
Design freeze + tooling order: Once design is validated, order die casting tooling
Pre-production samples: Die casting produces 50–100 sample parts for final validation
Production ramp: Die casting runs at production rate
Yuqing runs both CNC machining and (through partner foundries) die casting — so we can quote both processes and recommend the right hybrid for your project.
Material Considerations
|
Material |
CNC Machinability |
Die Castable? |
|
Aluminum A380, A383 |
Fair |
Yes — most common die casting alloy |
|
Zinc (Zamak 3, 5, 7) |
Fair |
Yes — easiest to die cast |
|
Magnesium AZ91D |
Fair |
Yes — lightest structural metal |
|
Steel (1018, 4140) |
Good |
No |
|
Stainless steel (304, 316) |
Fair |
No (use investment casting instead) |
|
Titanium Ti-6Al-4V |
Poor (slow) |
No |
|
Brass C360 |
Excellent |
No |
|
Copper C110 |
Fair |
No |
If your part must be in steel or titanium, die casting isn't an option — CNC (or machining + forging) is the path.
Frequently Asked Questions
When should I use CNC vs die casting?
Use CNC for prototypes, low volume (<500 pieces), tight tolerances, or non-castable materials. Use die casting for high volume (>1,000 pieces), complex 3D geometry, and cost-sensitive production runs.
What is the crossover point between CNC and die casting?
Typically 500–2,000 pieces depending on part complexity. Simple parts crossover higher (more pieces); complex parts crossover lower.
Is die casting cheaper than CNC?
For high volumes (1,000+ pieces), yes — die casting is typically 60–90% cheaper per piece after tooling amortization. For low volumes, CNC is cheaper because you avoid $5,000–$50,000 in tooling.
Can die casting hold tight tolerances?
Die casting typically holds ±0.1–0.3 mm. For tighter tolerances, secondary machining is required (which adds cost). For ±0.025 mm or tighter, CNC is required.
What materials can be die cast?
Common die casting materials: zinc alloys (Zamak 3, 5, 7), aluminum alloys (A380, A383, A384), magnesium alloys (AZ91D, AM60), and some brass alloys. Steels, titanium, and engineering plastics cannot be die cast.
How long does die casting tooling take?
6–12 weeks for tooling fabrication, sampling, and approval. CNC has no tooling lead time — parts in 7–15 days.
What is the minimum wall thickness for die casting?
1.0–1.5 mm for most alloys, depending on part size and material. Some specialized processes can go down to 0.5 mm, but at higher cost.
Does Yuqing offer both CNC and die casting?
Yes. Yuqing runs CNC machining in-house and coordinates die casting through partner foundries in Jiangsu and Zhejiang. We can quote both options and recommend the right process for your project. Send your STEP file and we'll provide a free process recommendation within 24 hours.
