DIE-CAST FITTINGS

Die cast wire rope and cable end fittings are created by injecting molten zinc directly onto a cable end inside a custom die. Lexco® Cable offers die cast fittings made to your specifications, no matter how unique your design. Specialty shapes such as barrels, bullets, Z-shape, L-shape, and the like are easily manufacturable as die cast fittings. Some of our “standard” fittings, such as ball ends and  eyelets can also be manufactured via die casting.

These fittings perform just as well as traditional fittings, and eliminate a good portion of the labor cost associated with conventional swaging. Most of our die cast fittings are made-to-order, and therefore require an associated tooling fee. However, customers with high volume orders may see significant cost savings over traditionally machined fittings.

Die-cast fittings are custom wire rope end fittings created by injecting molten zinc directly onto a cable end inside a custom die. This process allows for a wide range of specialized fitting shapes, including barrels, bullets, Z-shapes, L-shapes, ball ends, eyelets, and other custom cable end designs.

Lexco Cable offers made-to-order die-cast fittings for wire rope, aircraft cable, and custom cable assemblies. These fittings can be manufactured to unique specifications and may help reduce labor costs compared to conventional swaging or machined fittings, especially for high-volume production runs. For OEMs, industrial cable manufacturers, and custom wire rope assembly applications, die-cast fittings can provide a repeatable, cost-effective option for specialized cable end fittings.

Frequently Asked Questions About Die Cast Fittings

What are die-cast wire rope fittings?2026-08-06T20:43:21+00:00

Die-cast wire rope fittings are cable end fittings made by injecting molten zinc onto the end of a cable inside a custom die. This process forms the fitting directly around the cable end and can be used to create custom shapes such as barrels, bullets, ball ends, eyelets, Z-shapes, L-shapes, and other specialty wire cable ends.

When should I use die-cast fittings instead of swaged fittings?2026-08-06T20:43:47+00:00

Die-cast fittings may be a good option when the application requires a custom cable end shape, high-volume production, or reduced labor compared to conventional swaging. Swaged fittings are often used for standard wire rope terminations, while die-cast fittings are useful when the fitting shape is specialized or when repeatable production efficiency is important.

Can Lexco Cable make custom die-cast cable end fittings?2026-08-06T20:44:15+00:00

Yes. Lexco Cable can manufacture die-cast fittings to customer specifications, including unique shapes and made-to-order designs. Common options include barrels, bullets, ball ends, eyelets, Z-shaped fittings, L-shaped fittings, and other custom wire rope or aircraft cable end fittings.

Are die-cast fittings cost-effective for custom wire rope assemblies?2026-08-06T20:44:49+00:00

Die-cast fittings can be cost-effective for high-volume custom wire rope assemblies because they may reduce labor compared to conventional swaging or machined fittings. Most die-cast fittings are made to order and may require a tooling fee, so they are often best suited for production runs where volume can offset the initial tooling cost.

What information should I provide when requesting a quote for die-cast fittings?2026-08-06T20:45:26+00:00

When requesting a quote, provide the cable diameter, wire rope or aircraft cable construction, desired fitting shape, dimensions, material requirements, quantity, load requirements, and application details. If available, include drawings, samples, photos, specifications, or part numbers so Lexco can evaluate the design and quote the appropriate custom die-cast fitting.

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