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The traditional die casting process, a fundamental manufacturing technique widely utilized across automotive, electronics, and consumer goods industries, is primarily composed of four sequential steps commonly referred to as high pressure die casting. These four essential steps, which form the foundational framework for various modified die casting methodologies and advanced casting variants, include mold preparation, filling, injection, and drop sand removal. During the mold preparation phase, operators must carefully spray lubricant into the mold cavity, a critical procedural step that serves multiple functions including helping to regulate and control the temperature dynamics of the mold while simultaneously facilitating the effective release of the finished casting from the mold structure. Following proper lubrication and preparation protocols, the mold can then be securely closed, and the molten metal is subsequently injected into the prepared mold cavity using a high pressure injection system operating within a pressure range of approximately 10 to 175 megapascals, depending on the specific casting requirements and material specifications. Once the molten metal has been fully filled into the mold cavity, the pressure is strategically maintained at the operating level throughout the solidification period until the casting has completely solidified and achieved adequate structural integrity. After solidification is complete, the push rod mechanism then pushes out and ejects all the castings from the mold, and since modern mold designs may contain multiple cavities within a single mold structure, multiple castings can be efficiently produced and extracted during each individual casting cycle.

The high-pressure injection process in die casting operations functions by introducing molten metal into the mold cavity at elevated velocities and pressures, which generates a very fast filling sequence that allows the molten metal to penetrate and fill the mold before any portion of the material begins to solidify or set. In this manufacturing approach, even thin wall parts and sections that are conventionally difficult to fill due to their narrow cross-sections can successfully avoid the occurrence of surface discontinuities, voids, or incomplete material flow patterns that might otherwise compromise structural integrity. However, this rapid filling methodology simultaneously introduces a secondary challenge related to air entrapment, since the speed at which the molten metal advances through the mold cavity makes it increasingly difficult for air pockets and gases present within the mold space to escape before the material solidifies.