Die-cast Model Car: What is It? Casting Process and Sizes (2025)

Sizes of Die-cast Model Cars

Size scales of model cars

You can get die-cast cars in different sizes, tied in a fixed ratio with the size of real-life cars. For instance, 1:64, 1:43, 1:24, and 1:18., indicating the proportional size compared to the real vehicle. Smaller scales like 1:64 are common for toys, while larger scales like 1:18 die cast model cars are popular among collectors for their intricate detail. These models can represent vintage cars, modern vehicles, racing cars, or even fictional cars from movies and TV shows.

The table below outlines the most common size scales;

Metals/Alloys Used in Model Car Die Casting

Lightweight materials and durable metals and alloys are the first choices for die-casting model cars, such as aluminum alloys, zinc alloys, magnesium alloys, and sometimes copper alloys. Die casting manufacturers choose the suitable alloy depending on the desired strength, corrosion resistance, toughness, and aesthetic appeal.

The metal body of a die-cast model car

The typical metal/alloys to die cast a model car are as follows;

• Aluminum Alloys: Aluminium die casting, particularly alloy (A380) is popular for its strength, corrosion resistance, and castability, which is ideal for intricate model car parts​
• Zinc Alloys: Zamak series alloys offer superior dimensional stability and impact resistance in the casting of the model car.
• .Magnesium Alloys: Magnesium alloys( like AZ91D) are lightweight and strong. They are suitable for model cars requiring both strength and weight reduction are crucial​
• Copper Alloys: Although less common, copper alloys provide excellent electrical and thermal conductivity. They are used to cast specialized parts that require these properties​.

Read more: Aluminum Casting Manufacturer

The Process of Model Car Die Casting

The process of creating a die-cast model car body involves multiple steps, from design & prototyping to surface finishing. Each of the steps impacts how realistic the final model will look like as real-car.

The following are the steps of the model car die-cast process;

Step 1: Design Creation

Prepare the design of your model car to be cast. Following the machinery and capability available, dimension and tolerance of the design for optimal manufacturing. CAD could be employed for such designs. If you would like further refinement of your design, 3D printing or other rapid prototyping methods should be used.

Step 2: Mold Making

After testing the prototype and optimizing the design, choose the right material and method for making the dies, such as CNC machining, EDM, etc. The molds need to be engineered to perform under high pressure and thermal conditions. In addition, make sure that the cavities are smooth, as those will be capturing the details of the die-cast model car.

Step 3: Injection and Solidification

Die casting setup

This is the stage when molten metal, typically a zinc alloy, is forced into the mold cavity under high pressure. The flow of the molten captures all interior and exterior details. Then cool the mold to allow for solidification. The solidification time may depend on your cooling system, the metal type you’re casting, and the size itself.

Step 4: Ejection and Trimming

Once it has solidified, the casting is ejected from the mold. Then the excess materials are trimmed away to obtain the required dimensions and a smoother surface. So, your model car body is now ready for further finishing.

Step 5: Surface Finishing and Detailing

Model car bodies after surface finishing

The trimmed castings receive surface finishing processes of polishing and sanding to become smooth and free from defects. Following this, the base coats, colored layers, and clear finishes shall be applied using an airbrush. Finally, finish off with extra details like decals and interior components.

Step 6: Final Assembly

Final assembly of die-cast car

All the components are assembled with the die-cast body: interior details, windows, wheels, etc. Quality control checks are mandatory at the final assembly to ensure precision and that all standards for your miniature replica are met.

How to Choose a Die-cast Model Car Manufacturer?

Die-cast car body of a custom design

Whether you are just an enthusiastic collector who needs a few custom models or a business selling such cars, choosing the right Die casting manufacturers for your model car body involves different considerations. Let’s discuss them in brief.

1. Quality and Craftsmanship

Check the detailing capability of the manufacturer regarding accuracy in features, finishes, and overall build quality. High-quality models have precise detailing, tight assembly, and durable material.

2. Available Equipment

Since final quality depends on the available machinery and tooling facility, check tonnage capability, size, and other information of potential manufacturers.

3. Brand Reputation

Look at the die cast model car manufacturers that are popular among the collectors already. Meanwhile, brands like Autoart, Kyosho, and CMC sell their own models, they do not produce your designs. So, the best idea is to search for the OEMS.

4. Product Range

Consider whether the manufacturers have the capability of producing a diverse range of models, scales, and types of cars that meet your interests or business needs. Some die cast model car manufacturers concentrate on certain scales or one type of vehicle.

5. Pricing and Value

Decide whether the pricing of the manufacturer reflects the committed quality and intricate detailing of die-cast car models. While it’s correct that models with higher detailing are often more expensive than simple models.

6. Availability and Distribution

Ensure that the shipping or distribution channel followed by the manufacturer is locally available for purchase on many occasions. Limited availability can impact procuring a specific model and will further reflect an impact on pricing.