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The Liquid Cooling Era: How Zinc-Aluminum Alloy Die Casting is Cooling Down Data Centers and Communication Equipment?
Created on 08.31
The Liquid Cooling Era: How Zinc-Aluminum Alloy Die Casting is “Cooling Down” Data Centers and Communication Equipment?
AI算力集群的爆发式增长，正在倒逼散热技术加速从“风冷时代”迈向“液冷时代”。随着芯片功耗持续攀升，传统风冷方案逐渐触及物理极限，液冷成为AI数据中心的主流选择。在这场散热革命中，看似不起眼的锌铝合金压铸件，正扮演着连接算力与散热的桥梁角色。
Thermal Pressure Escalates: Die Castings Evolve from Structural Parts to Core Components
A telling data point: 800G optical transceivers consume approximately 25-30W, while 1.6T modules more than double that figure to over 45W. This means thermal management has been elevated from a “secondary consideration” for structural components to a core metric that determines equipment stability and reliability.
This very shift is redefining the value of die castings. In communication equipment, AI servers, and data center applications, zinc-alloy and aluminum-alloy die castings have formed a clear division of labor based on their respective strengths:
- Zinc Alloy: The “EMI Shield” for Precision Small Components
. Precision small parts such as optical communication module housings and high-speed connector shells are the home turf of zinc-alloy die casting. Zinc alloys enable thinner wall sections and finer detail while providing inherent electromagnetic interference (EMI) shielding and direct plating compatibility—features that have made them the standard material for thumb-sized parts like optical module housings.
Aluminum Alloy: The “Thermal Conduction Workhorse” for Large-Scale Heat Dissipation. Components such as server rack thermal parts and liquid cold plate frames—which must balance thermal conductivity, lightweighting, and structural rigidity—are the domain of aluminum-alloy die casting. Aluminum’s excellent thermal conductivity makes it an ideal choice for liquid cooling assemblies and heatsink housings.
Industry Trends: How Are Leading Players Positioning Themselves in AI Compute Die Casting?
The momentum and direction of this are clearly visible in the moves of industry leaders. Huayang Group, a representative player in the precision die casting sector, offers a noteworthy case study:
- Zinc Alloy Business: Die-cast components for optical communication modules and high-speed connectors have achieved mass production, generating approximately RMB 600 million in revenue in 2025, with two consecutive years of rapid growth.
- Aluminum Alloy Business: Thermal components for AI server racks have secured project nominations from international customers, and the company has won orders worth RMB 400 million over the product lifecycle in the server die-cast structural parts segment.
- Capacity Expansion: To meet the surging demand for AI-related orders, Huayang is simultaneously advancing die-casting capacity expansions across multiple locations including Huizhou, Suzhou, and Thailand, with new capacity expected to come online gradually in 2026.
This trend indicates that die-casting companies equipped with automotive-grade precision die-casting capabilities, multi-material process stacks, and turnkey delivery capabilities are earning their place in the AI compute hardware supply chain.
From General Manufacturing to AI Compute: Capability Alignment for Die-Casting Factories
For enterprises with established zinc-aluminum alloy die-casting production capabilities, the key to entering this track lies in the precise migration and upgrading of capabilities.
Take, for example, a turnkey die-casting factory with a monthly production capacity of 2 million parts and IATF 16949 automotive certification. The alignment between its existing capabilities and the demands of AI data center die castings is illustrated below:
Capability Dimension | Existing Foundation | Data Center/Liquid Cooling Requirements | Target Product Categories |
Precision Die Casting | Zinc-alloy phone housings, automotive parts, patented molds that reduce cooling cycle time | Thin-wall precision and dimensional consistency for optical module housings and high-speed connector shells | Optical Communication Module Housings |
Aluminum Mass Production | General aluminum die castings such as LED lamp housings and speaker enclosures | Structural strength and thermal conductivity for server rack thermal parts and liquid cooling module frames | AI Server Structural Parts |
Turnkey Process | house mold design, CNC machining, polishing, plating, and painting | Reduced supply chain complexity, high-precision post-processing and surface finishing | Various Precision Structural Parts |
Quality System | ISO9001/14001 IATF 16949 automotive certification, ISO 9001/14001 | Automotive-grade quality control is transferable to AI compute hardware with extremely high reliability requirements | All Categories |
Product Category Opportunity Analysis: A Gradual Path from Periphery to Core
Based on processing capabilities and market demand, the product category pathway for die-casting companies entering the liquid cooling and data center segment can be divided into three tiers:
Tier 1: Mature Entry Categories (High Process Match)
- Communication Equipment Cavities: 5G base station RF unit housings, high-power power module enclosures. Aluminum die-casting processes are mature, with clear EMI shielding and thermal dissipation requirements.
- Data Center Peripheral Structural Parts: Internal rack brackets, module frames, and other non-core thermal components.
Tier 2: Value-Added Categories (Precision Upgrade Required)
- Optical Module Housings (Zinc Alloy): Fast-growing market with leading manufacturers already in mass production. Requires further improvements in thin-wall molding and dimensional control precision on top of existing zinc die-casting capabilities.
- High-Speed Connector Shells (Zinc Alloy): Paired with optical module housings, equally demanding in terms of precision and EMI shielding performance.
Tier 3: Strategic Positioning Categories (Technology Reserve Required)
- Liquid Cooling Module Assemblies (Aluminum): Industry leaders are transitioning from "supplying structural parts" to "possessing liquid cooling module integration capabilities." This requires technical accumulation in thermal design and fluid management, making it suitable as a medium-to-long-term strategic direction.
The convergence of liquid cooling and AI compute power is opening a brand-new growth channel for the zinc-aluminum alloy die-casting industry. For manufacturers equipped with precision die-casting capabilities, complete process chains, and automotive-grade quality control systems, starting with structural parts for communication industrial equipment and gradually upgrading to high-value-added categories such as optical modules and high-speed connectors is a realistic path to enter this space. As compute density continues to rise, the value of die castings in thermal solutions is only just beginning to be reevaluated.
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